DBM 03

User's Manual

GB-4019 Rev.9 - July/98

DBM 03 - USER'S MANUAL

Rev Date Description Updated Pages

.
0 June/95 Initial Release
1 22/June/95 Correct miscellaneous errors 52, 84, 111
2 6/July/95 Correct miscellaneous errors 7, 27, 28, 29, 33, 66, 68, 84,
86, 91
3 28/Sept/95 Correct miscellaneous errors 55, 73, 83, 94
4 24/Oct/95 Add facilities to change DBM01 with DBM03 52
5 6/May/96 Add reference to DBTALK program and 7, 28, 33, 48, 49, 50, 51, 52,
pinouts of RS232/RS485 converter; correct 63, 79, 80, 87, 90, 121
OC, OV, VO commands; update personality
card; add DBM-PS internal card jumpers;
correct miscellaneous errors
6 30/July/96 Add EMC paragraph; update motor connector 1, 3, 5, 8, 33, 35, 42, 44, 46,
pinout (Fig.1.13); correct soft start 61, 86
configuration (Fig.2.1, 2.2); update resolver
wiring (Fig.2.3) according to EMC; correct
miscellaneous errors
7 6/Feb/97 Add Section 6 (EMC); change par.1.6 (CE- 1, 2, 5, 6, 8, 13, 24, 27, 29,
marking); update all wiring figures according 30, 31, 34, 35, 38, 45, 46, 48,
to EMC; add Appendix A (serial link 49, 52, 56, 75, 82, 85, 88,
multidrop); add Appendix B (Dbtalk 123, 124,125, 126, 127, 128,
communication program); update par.2.2.7 129, 130, 131, 132, 133
(personality card); correct miscellaneous
errors
8 23/May/97 Update standards with EN 61800-3, EMC 3, 5, 6, 8, 9, 11, 25, 37, 42,
product standard; correct fig.6.8 43, 44, 48, 49, 52, 56, 57, 72,
(EMC/Equipotential bonding); update 220Vac 75, 98, 99, 101, 105, 123,
with 230Vac; correct tab.3.5 (IT/PC); correct 125, 128, 129, 132, 133
the leakage current of EMC filters; correct
miscellaneous errors
9 6/July/98 Add Appendix C, D and E; add default values 2, 43, 48, 55, 83, 85, 94, 123,
for keyboard setup; add reset to enable SE 125, 130, 134, 135, 136
command; correct miscellaneous errors
 Table of Contents

Introduction page 3

Section 1 general features 5

Description standard features 5
technical data 6
interfaces 7
protections 7
CE marking 8
system wiring 8
configurations 8
internal jumpers 13
dimensions 36
fans 37
recovery circuit 37
block diagrams 39

Section 2 wiring 43
Installation transformer/autotransformer connection 43
soft start 45
resolver wiring 47
motor power wiring 47
connection to PC 48
installation 48
keyboard or opto priority 49
autophasing 49
personality card jumpers 52
resolver to encoder (optional) 53
operation 57

Section 3 general features 58

Commands and commands 60
Protections protections 92

Section 4 98
Troubleshooting

Section 5 introduction 114

Principles of torque generation 114
Operation current control loop 117
speed and position sensing 119
speed loop 121

1 - 6/July/98
Section 6 European Directive 123
EMC filtering 123
wiring and grounding 126
recovery resistor 128
screening 129
safety aspects 130

Appendix A internal jumpers 131

Multidrop personality card jumpers 131

Appendix B dbtalk communication program 132

Dbtalk

Appendix C module replacement 134

Appendix D input sizing 135

Appendix E mechanical brake 136

2 - 6/July/98
Introduction
This manual provides the necessary information for a proper installation and an effective use
of DBM Digital Drives in the possible different configurations.

Its contents allow technicians to understand how the system works and to carry out
installation procedures.

The safety instructions provided in this Manual are included to prevent injury to personnel
(WARNINGS) or damage to equipment (CAUTIONS).

To emphasize the differences between new DBM 03 User's Manual and old DBM 01 User's
Manual, a vertical line in the left margin of the text indicates new items.

Accident Protection

Keep to the general security rules for electrical equipment's. DBM-PS power supply is
electrically connected to mains.

WARNING: High Voltage. L+ and L- pins and BUS BAR can have voltage
≥300Vdc even after switching off (capacitive voltage). Discharge
Time Approx. 6 Minutes.
WARNING: High Voltage. The recovery resistor is connected to the Bus Bar’s
and can have voltage ≥300Vdc.
WARNING: do not touch recovery resistor during operation to avoid scalds.
WARNING: when required for an emergency stop, opening motor phases must
be preceded by disabling the axis. The delay time must be at least
30 ms.
WARNING: the drive should be located in an environment that is free from dust,
corroding fumes and fluids. In condensing atmospheres, the cabinet
must be provided with an anti-condensation device.

Tightening Torque

CAUTION: do not exceed the tightening torque of the table

Screw Tightening torque

Thread [Nm] [lb in]
M3 1.00 8.85
M4 3.00 26.55
M5 6.00 53.10
M6 8.00 70.80
M8 20.0 177.0

3 - 6/July/98
4 - 6/July/98
SECTION 1 - DESCRIPTION

1.1 General Features

The modular DBM series drives offer digital speed loop and digital analog interfaces. They
are suitable for use with 4-quadrant, brushless motors having sinusoidal back e.m.f. .
Construction allows the use of the power amplifiers only, if required for easy CNC interface.

Hardware circuits are reduced by using Isolated Gate Bipolar Transistor (IGBT) components
in the power section.

Control technique is sinusoidal.

The unique advantages of the digital technology (16/32 bit DSP based) are:

• Simplified installation through optimization of control parameters via software.

• No potentiometer adjustments.
• Autophasing.
• Easy adaptation to different applications: e.g. you may change the PI gain variables and
choose between speed or torque control.
• Compact assembly: up to 3-axis control from a single module.
• Flexibility: up to 99 axes, 240A peak per axis.

1.2 Standard Features

• Three-phase full bridge with IGBT

• Current reference refresh time: 100 µs
• Phases refresh time: 300 µs
• R/D resolution automatically switched according to actual speed for optimum system
performance (between 10 and 16 bit)
• Resolution of A/D converter: 12 bit or 14 bit (optional)
• 4 different velocity control structures to meet the most challenging requirements
• Digital low-pass filter on speed loop
• Over travel limit switches available (when Expansion is not present)
• Totally programmable control and interface parameters
• Current bandwidth (analog) > 1kHz
• Dead point: absent
• Speed ratio: 1:4000
• Static current gain 10 5 A/V
• Max operating temperature / humidity: 45 °C (113 °F) / 90%
• Derating for altitude > 1000 m (3333 feet): 1% per 100 m (333 feet)
• Storage temperature: -10 to +70 °C

5 - 6/July/98
1.3 Technical Data

DBM Module
Input voltage : 300Vdc, ±10%
Three-phase output voltage : 180V

DBM-PS Power Supply

Three-phase input voltage : 230Vac, ±10%, 50/60 Hz
Auxiliary power supply input voltage : 110Vac (optional) or 230Vac, ±10%, 50/60 Hz
Auxiliary input power : 55W for 3-axis module, 60W for fans pair
BUS BAR output voltage : 300Vdc

230

230

6 - 6/July/98
1.4 Interfaces

Digital
• Output for simulated encoder (optional)
• Serial Link RS485(1200-19200 Baud) full-duplex to manage:
- Acceleration limits
- Autophasing
- Control parameters
- Monitoring of internal parameters
- Range of analog interface
- System status
• Output for Drive OK axis 1, axis 2, axis 3 (TTL compatible)

On-Off (Optoisolated)
• Drive OK
• Drive Enable
• Motor OK
• Reference Enable

Analog
• Input velocity (see MR command)
• Resolver differential input signals
• Peak current limit input
• Output tachometer (see ET command)
• Max current, velocity reference, velocity error outputs (see ES, SO commands)

1.5 Protection

Module
• Auxiliary voltage out of tolerance
• BUS BAR overvoltage
• BUS BAR undervoltage
• Motor phase grounded
• Motor overtemperature
• Module overtemperature
• IT protection
• Abnormal resolver signal
• Short circuit on motor phases
• Non-coherent three-phase sequence
• Actual speed versus reference error

Power Supply
• Overtemperature
• Recovery unit not OK

7 - 6/July/98
1.6 CE-Marking

Starting from Jan/97, DBM03 drives have CE-marking according to Low Voltage Directive.
Starting from Apr/97 the CE-marking refers also to EMC Directive (see Section 6).
A Declaration of Conformity is available.

The Low Voltage Directive applies to all electrical equipment designed to use with a voltage
rating of between 50 Vac and 1000 Vac and between 75 Vdc and 1500 Vdc.

The CE-marking states that the electrical equipment has been constructed in accordance
with good engineering practice in safety matters in force in the European Community and it
does not endanger the safety of persons, domestic animals or property when properly
installed and maintained and used in applications for which it was made.

DBM 03 drives meet the following standard related to Low Voltage Directive:
CEI EN 60204-1 (1993) par. 6.2.3, 20.3, 20.4

1.7 System Wiring

All of the analog and digital signal connectors, auxiliary power supplies and I/O interfaces are
front-connected to the unit.

Connectors for auxiliary power supply are made via Molex type connectors. Motor power are
connected via a Harting type connector, while I/O connectors use a Weildmuller type
connector.

All other connectors are made via D-type connectors.

All signals are positive logic:

active = +15V
not active = 0V (or not connected)

1.8 DBM Configurations

Three configurations are possible for the module:

DBM-3A: 3-axis module (see Fig. 1.3)

DBM-2A: 2-axis module (see Fig. 1.4)
DBM-2E: 2-axis module with expansion (see Fig. 1.5)
DBM-L3A: 3-axis 180 mm module (see Fig. 1.6)
DBM-L2A: 2-axis 180 mm module (see Fig.1.7)

8 - 6/July/98
FIG. 1.1 - Inter module wiring

230 VAC

3 x 230 Vac

9 - 6/July/98
FIG. 1.2 - DBM-PS Power Supply

10 - 6/July/98
Tab. 1.1 - DBM-PS Power Supply (See Fig. 1.2)

Pos. Name
1 R "L1" phase, three-phase input voltage 230Vac
2 S "L2" phase, three-phase input voltage 230Vac
3 T "L3" phase, three-phase input voltage 230Vac
4 GND Ground
5 RR Recovery resistor
6 RR Recovery resistor
7 AUX Auxiliary power supply 230Vac (110Vac as option)
8 AUX Auxiliary power supply 230Vac (110Vac as option)
9 Yellow LED BUS BAR voltage > 40Vdc
PWR-BUS
10 Red LED Recovery unit fault
DBR FAULT
11 N.C.
12 Red LED Module overtemperature via PTC (threshold 80 °C)
OVER
TEMP
13 Green LED Auxiliary power supply OK
AUX
POWER
14 J2 RS485 output port to drives and power control fault
15 J10 RS485 input port
16 J1 Auxiliary power supply flat connector
17 GND Ground
18 L- BUS BAR -HV 300Vdc
19 L+ BUS BAR +HV 300Vdc

11 - 6/July/98
Tab. 1.2 - DBM-PS Power Supply - J1 Connector
Auxiliary Power Supply

Pos. Name
1 N.C. (Not connected)
2 N.C.
3 - 15Vdc referred to -HV (300Vdc)
4 +18Vdc referred to -HV (300Vdc)
5 150kHz square wave to high side drives
6 N.C.
7 +18Vdc referred to logic 0V
8 - 18Vdc referred to logic 0V
9 +8Vdc referred to logic 0V
10 +8Vdc referred to logic 0V
11 Logic 0V
12 Resolver 0V
13 10 kHz sinusoidal wave for resolver and synchronism (carrier)

Tab. 1.3 - DBM-PS Power Supply - J2 Connector

RS485 Port Signal and PWRS Control

Pos. Name
1 + Rx (RS485 serial link)
2 N.C.
3 + Tx (RS485 serial link)
4 PWRS fault 1 - power supply binary coded faults (level 1)
5 + 5Vdc input referred to logic 0V
6 - Rx (RS485 serial link)
7 Logic 0V
8 - Tx (RS485 serial link)
9 PWRS fault 2 - power supply binary coded faults (level 2)

Note: Rx and Tx are the receiving and transmitting signals with reference to the drive. In the
rest of the manual "RS485 serial link", referring to Rx and Tx, will not be specified anymore.

12 - 6/July/98
In case of fault, the type of fault is as follows:

J2/pos. 4 J2/pos. 9
0 0 OK
0 1 DBR FAULT. Recovery fault
1 0 OVER TEMP. Overtemperature
1 1 PHASE FAULT.

Tab. 1.4 - DBM-PS Power Supply - J10 Connector

RS485 Port

Pos. Name
1 +Rx
2 N.C.
3 +Tx
4 N.C.
5 +5Vdc output referred to logic 0V for power supply
6 -Rx
7 Logic 0V
8 -Tx
9 N.C.

1.8A DBM-PS Internal Card FIG. 1.A - DBM-PS Card Jumpers

Jumpers

JP1 closed (default) = connects a 120 Ω

resistor between RX+ and RX-.
JP2 closed (default) = connects TX- of
serial link to 0V via pull-down resistor
JP3 closed (default) = connects TX+ of
serial link to +5V via pull-up resistor

13 - 6/July/98
FIG. 1.3 - DBM 3-Axis Module

14 - 6/July/98
FIG. 1.4 - DBM 2-Axis Module

15 - 6/July/98
FIG. 1.5 - DBM 2-Axis and Expansion (optional) Module

16 - 6/July/98
FIG. 1.6 - DBM-L (180 mm) 3-Axis Module

17 - 6/July/98
FIG. 1.7 - DBM-L (180 mm) 2-Axis Module

18 - 6/July/98
FIG. 1.8 - EBM Expansion Module (optional)

19 - 6/July/98
Tab. 1.5 - DBM Axis Module (See Fig. 1.3 to 1.8)

Pos. Name
1 J9 Motor phases (M1-M2-M3) connector
2 J6 M3 Resolver M3 connector
3 J5 M2 Resolver M2 connector
4 J4 M1 Resolver M1 connector
5 J8 I/O signals connector
6 J7 connector for analog references and simulated encoder output
7 Red LED generic fault: the fault can correspond, according to the type, to a
DRFV LED on the front end; if other red LED's are not on, out of the
considered one, it is necessary to interrogate the drive via serial
link to know the fault reason (see FA command)
8 Red LED Watch dog - signal; microprocessor circuit faults; this LED is on
WTD during reset
9 Red LED Resolver 3 fault - signal; resolver M3 fault, sin /cos signals
RF3 interrupted, short circuit between signals or 10kHz carrier
abnormal
10 Red LED Resolver 2 fault - signal; resolver M2 fault, sin /cos signals
RF2 interrupted, short circuit between signals or 10kHz carrier
abnormal
11 Red LED Resolver 1 fault - signal; resolver M1 fault, sin /cos signals
RF1 interrupted, short circuit between signals or 10kHz carrier
abnormal
12 Red LED Motor M3 overtemperature
OVT3
13 Red LED Motor M2 overtemperature
OVT2
14 Red LED Motor M1 overtemperature
OVT1
15 Trimmer all axes peak current control (only for setup technicians); if current
ILIMIT limit is required see IL, DL, AL commands
16 Push digital control card reinitialization
button
RESET
17 Red LED module overtemperature
DRV OVT
18 Red LED short circuit on axis 1 (motor phases)
SHRT CCT
19 Red LED short circuit on axis 2 (motor phases)
SHRT CCT
20 Red LED short circuit on axis 3 (motor phases)
SHRT CCT
21 J2 RS485 input port and PWRS-fault signals connector
22 J3 Expansion connector for two axis module; on three axis module
some pins of this connector are used as test points
23 Green LED Reference enabled - signal: three - axis speed reference enable
REF EN (see Tab. 1.12/ pos. 16)

20 - 6/July/98
 24 Green LED Axis 1 enable (see also ON command)
DRIVE
EN 1
25 Green LED Axis 2 enable (see also ON command)
DRIVE
EN 2
26 Green LED Axis 3 enable (see also ON command)
DRIVE
EN 3
27 Green LED Auxiliary power OK
POWER
OK
28 Personality card: it contains drive setup in a non volatile memory
29 J1 Auxiliary power supply flat connector
30 GND Ground
31 L- BUS BAR -HV 300Vdc
32 L+ BUS BAR +HV 300Vdc
33 J10 Motor phases (M1-M2-M3) connector for DBM-L module

Tab. 1.6 - DBM Module, EBM Expansion - J1 Connector

Auxiliary Power Supply

Pos. Name
1 N.C.
2 N.C.
3 - 15Vdc referred to -HV (300Vdc)
4 + 18Vdc referred to -HV (300Vdc)
5 150kHz square wave to high side drives
6 N.C.
7 + 18Vdc referred to logic 0V
8 - 18Vdc referred to logic 0V
9 + 8Vdc referred to logic 0V
10 + 8Vdc referred to logic 0V
11 Logic 0V
12 Resolver 0V
13 10kHz sinusoidal wave for resolver and synchronism (carrier)

21 - 6/July/98
Tab. 1.7 - DBM Module - J2 Connector -
Power Supply Flat and RS485 Port Signals

Pos. Name
1 +Rx
2 N.C.
3 +Tx
4 PWRS fault 1 - power supply binary coded faults
5 +5Vdc output referred to logic 0V
6 -Rx
7 logic 0V
8 -Tx
9 PWRS fault 2 - power supply binary coded faults

Note: In case of fault, the type of fault is as follows:

J2/pos. 4 J2/pos. 9
0 0 OK
0 1 DBR FAULT. Recovery fault
1 0 OVER TEMP. Overtemperature
1 1 PHASE FAULT.

22 - 6/July/98
Tab. 1.8 - DBM Module - J3 Connector
Expansion Connection

Pos. Name
1 0V common
2 Auxiliary voltages referred to logic 0V not OK input signal
3 Phase U reference current output signal
4 Torque enabled output signal
5 Short circuit input signal
6 Overtemperature input signal
7 Expansion present input signal
8 Overtemperature output signal
9 N.C.
10 Phase V reference current, output signal
11 Overtemperature input signal
12 Non - coherent current input signal
13 BUS BAR fault input signal
14 Auxiliary voltages referred to - HV (300Vdc) not OK, input signal
15 N.C.

23 - 6/July/98
FIG. 1.9 - Limit Switches Wiring

DBM 04

1 0V
2 C W L im it sw itch a xis 1

5 C C W L im it sw itch a xis 1

6 C W L im it sw itch a xis 2

12 C C W L im it sw itch axis 2

13 C W L im it sw itch a xis 3

14 C C W Lim it s w itc h a x is 3

ca b le sh ield m us t b e R F *
co n ne cte d to g ro un d J3

g ro u n d in g o f s h ie ld
v ia co n n e cto r s h e ll
*=see Section 6

24 - 6/July/98
Tab. 1.9 - DBM Module J3 Connector (when EBM Expansion is not present)
Limit Switches Connection (see Fig. 1.9)

The J3 connector allows, when the Expansion is not present, the availability of CW/CCW limit
switches for each axis. With the input enabled (to 0V), the rotation is disabled in one direction
and enabled in the other direction.
When the Expansion is present, the J3 connector is used for signal connection to the
Expansion module.

Pos. Name
1 0V common
2 CW limit switch, axis 1
3 N.C.
4 N.C.
5 CCW limit switch, axis 1
6 CW limit switch, axis 2
7 N.C.
8 N.C.
9 N.C.
10 N.C.
11 N.C.
12 CCW limit switch, axis 2
13 CW limit switch, axis 3
14 CCW limit switch, axis 3
15 0V common

Note: CW means clockwise rotation when viewed from shaft end, with default DI command.

25 - 6/July/98
Tab. 1.10 - DBM Module - J4 - J5 - J6 Connectors
Resolvers

Pos. Name
1 cos Differential cos signal non-inverted input

2 cos Differential cos signal inverted input

3 Shield Internally connected to 0V common

4 sin Differential cos signal non-inverted input

5 sin Differential cos signal inverted input

6 PTC Motor PTC input

7 0V 0V common. Special for 10kHz carrier
8 PTC Motor PTC input
9 V ref 20 Vpp/ 10kHz sinusoidal output signal for supplying primary
resolver winding (carrier)

26 - 6/July/98
FIG. 1.10 - Speed Reference Wiring

DBM 04
C NC

REF

REF

0V

0V

J7

c a b le sh ie ld m u s t b e R F g ro u n d in g o f sh ie ld
c o n n e cte d to th e h o u s in g v ia c o n n e c to r sh e ll

D IF F E RE N T IA L IN P U T

D B M 04
CNC

REF
0 V REF

0 V

J7

c a b le s h ie ld m u s t b e R F g ro u n d i n g o f s h i e ld
c o n n e c te d to th e h o u s in g v ia c o n n e c to r s h e ll

U N IP O L A R IN P U T

27 - 6/July/98
Tab. 1.11 - DBM Module - J7 Connector
Analog Inputs and Simulated Encoder Outputs

Pos. Name
1 Logic 0V (it can be used as common for analog output
supplies ±15V)
2 A1 encoder output: inverted phase A - motor 1
3 B1 encoder output: inverted phase B - motor 1
4 C1 encoder output: inverted phase C - motor 1
5 A2 encoder output: inverted phase A - motor 2
6 B2 encoder output: inverted phase B - motor 2
7 C2 encoder output: inverted phase C - motor 2
8 A3 encoder output: inverted phase A - motor 3
9 B3 encoder output: inverted phase B - motor 3
10 C3 encoder output: inverted phase C - motor 3
11 TP2 Testing point 2
12 ILIMIT3 Analog input I limit axis 3, referred to analog 0V
0V = zero current
+10V (or not connected) = max current
13 ILIMIT2 Analog input I limit axis 2, referred to analog 0V (0 to +10V )
14 ILIMIT1 Analog input I limit axis 1, referred to analog 0V (0 to +10V )
15 Shield. Internally connected to 0V
16 REF3 Differential inverting analog input for the speed reference
signal (or torque ref. signal, see TC command) axis 3, max
range ±10V (see MR command). See Fig. 1.10.
17 REF2 Differential inverting analog input for the speed reference
signal (or torque ref. signal, see TC command) axis 2, max
range ±10V (see MR command). See Fig. 1.10.
18 REF1 Differential inverting analog input for the speed reference
signal (or torque ref. signal, see TC command) axis 1, max
range ±10V (see MR command). See Fig. 1.10.
19 +15Vdc output (I max = 30mA)
20 A1 encoder output: phase A - motor 1
21 B1 encoder output: phase B - motor 1
22 C1 encoder output: phase C - motor 1
23 A2 encoder output: phase A - motor 2
24 B2 encoder output: phase B - motor 2
25 C2 encoder output: phase C - motor 2
26 A3 encoder output: phase A - motor 3
27 B3 encoder output: phase B - motor 3
28 C3 encoder output: phase C - motor 3

28 - 6/July/98
 29 TP1 Testing point 1
30 Shield. Internally connected to 0V
31 DRIVE Drive OK output, axis 1. Imax=5mA.
OK 1 0V=not OK
+5V=OK
32 DRIVE Drive OK output, axis 2. Imax=5mA.
OK 2 0V=not OK
+5V=OK
33 DRIVE Drive OK output, axis 3. Imax=5mA.
OK 3 0V=not OK
+5V=OK
34 REF3 Differential non-inverting analog input for the speed reference
signal (or torque ref. signal, see TC command) axis 3, max
range ±10V (see MR command). See Fig. 1.10.
35 REF2 Differential non-inverting analog input for the speed reference
signal (or torque ref. signal, see TC command) axis 2, max
range ±10V (see MR command). See Fig. 1.10.
36 REF1 Differential non-inverting analog input for the speed reference
signal (or torque ref. signal, see TC command) axis 1, max
range ±10V (see MR command). See Fig. 1.10.
37 - 15Vdc output (I max = 30mA)

REMARK: in DBM 01 version positions 31, 32 and 33 were assigned to differential inverting
I Limit analog inputs. If this option was used, to change DBM 01 with DBM 03 it is necessary
to properly specify differential analog I Limit input in the order (CG5502 code).

29 - 6/July/98
FIG. 1.11- Input/Output Wiring

+24V

+ 24V Pow er Supply

0V

CNC D BM
+2 4 V
0V 8 O p to isola te d inp u t co m m o n
D rive E n ab le * D rive E n ab le
R e f. E n a b le 16 R e fe re nce E n a b le

9 D rive OK
D rive O K O p to iso la te d O u tp u t
10
11 M o to r O K
M o to r O K 12 O p to iso la te d O u tp u t

ca b le sh ie ld m u st b e R F g ro u n d in g o f sh ie ld J8
co n n e cte d to th e h o u sin g via h o se cla m p
* = p in n u m b e r is a xis de pe n de n t

+ 2 4 V P O W E R SU P P L Y

DBM

6 0V C om m on
7 + 15 V d c o utp u t

8 O p to isola ted inp u t co m m o n

* D rive E n able

16 R e fe re nce E n a b le

J8

* = pin n u m b e r is a xis d ep e nd e n t

+ 1 5 V IN T E R N A L SU P P L Y
(fo r d rive test)

30 - 6/July/98
Tab. 1.12 - DBM Module J8 Connector
I/O Commands and Signals

Pos. Name
1 TACHO TEST 1 tachometer analog output, axis 1. Range: see ET command
2 TACHO TEST 2 tachometer analog output, axis 2. Range: see ET command
3 TACHO TEST 3 tachometer analog output, axis 3. Range: see ET command
4 ANALOG OUT 1 analog output 1. Max current, velocity reference or velocity
error outputs. See ES and SO commands.
5 ANALOG OUT 2 analog output 2. Max current, velocity reference or velocity
error outputs. See ES and SO commands.
6 0V 0V common
7 +15V +15Vdc output (Imax = 30mA)
8 OPTO 0V Optoisolated 0V
9 DRIVE OK Collector of Drive OK optoisolator
10 DRIVE OK Emitter of Drive OK optoisolator
11 MOTOR OK Collector of Motor OK optoisolator
12 MOTOR OK Emitter of Motor OK optoisolator
13 DRIVE EN1 Drive enable 1: optoisolated input for axis 1 torque enable.
See Fig. 1.11.
14 DRIVE EN2 Drive enable 2: optoisolated input for axis 2 torque enable.
See Fig. 1.11.
15 DRIVE EN3 Drive enable 3: optoisolated input for axis 3 torque enable.
See Fig. 1.11.
16 REF EN Reference enable: optoisolated input for the confirmation of
the common reference to the three axis (REF EN not active
means no speed reference or zero torque)
17 N.C.
18 REM RESET Remote reset: optoisolated input for logic section reset,
equivalent to push button on the front panel

31 - 6/July/98
Tab. 1.13 - EBM Expansion (optional) - J3 Connector
(See Fig. 1.8)

Pos. Name
1 0V common
2 Auxiliary voltages referred to logic 0V not OK output signal
3 Phase U reference current input signal
4 Torque enabled input signal
5 Short circuit output signal
6 Overtemperature output signal
7 Expansion present input signal
8 Overtemperature input signal
9 NC
10 Phase V reference current, input signal
11 Overtemperature output signal
12 Non - coherent current output signal
13 BUS BAR fault output signal
14 Auxiliary voltages referred to +HV (300Vdc) not OK output signal
15 N.C.

32 - 6/July/98
Tab. 1.14 - Input/Output Characteristics

Optoisolated inputs z in =1.2 kΩ

Drive enable 1,2,3 I nom = 10 mA
Reference enable Imax = 20 mA
Remote reset Vmin = 15Vdc
Vmax = 25V
Optoisolated outputs z out = 1.2 kΩ
Drive OK I max = 20 mA
Motor OK Vnom < 25 Vdc
Analog tacho z out = 100 Ω
outputs 1,2,3 I max = 5 mA
Range: see ET command
Gain error = ±10% over production spread
Max linearity error: ±2% over full range
Analog outputs z out = 100 Ω
Analog Out1 I max = 10 mA
Analog Out2 Range: see ES command
Full scale = ±10V
Velocity reference z in > 20 kΩ
inputs 1,2,3 Range = see MR command
Vmax = 12 V
Drive OK outputs TTL compatible
1, 2, 3 Fan-out = 5 LS-loads
I max = 5 mA
Simulated Encoder z out = 100 Ω
differential output Full scale = 7V (differential)

33 - 6/July/98
FIG. 1.12 - Motor Phases Wiring (only one axis shown)

M otor DBM 04

U U

V V

W W

g ro u n d g ro u n d

J9/J10/J11

grounding of shield grou n din g of s hie ld

via connector clamp via connector clam p
(or RF connection to
the ground screw in
case of terminal board)

FIG. 1.13A DBM03 Module. J9 Connector. Motor Power (wiring side)

The configuration of this connector depends on the different combinations of sizes .

Notes: M1 always corresponds to the more powerful axis. M3 must not be connected in 2 axis configuration.

34 - 6/July/98
FIG. 1.13B DBM03-L (180 mm) Module. J9 and J10 connectors. Motor Power (wiring
side)

The configuration of these connectors depend on the different combinations of sizes .

Notes: M2 always corresponds to the more powerful axis. M3 must not be connected in 2 axis configuration. For
U-V-W positions see Fig. 1.13A.

35 - 6/July/98
1.9 Dimensions
FIG. 1.14 - Dimensions (in mm).

Note: for DBM-L modules (180 mm), dimensions are the same as two side by side standard modules

36 - 6/July/98
1.10 Fans

The ventilation is provided by fans mounted under the modules. The size and the number of
fans are according to the system configuration.

Fan input voltage is 230 Vac (or 110 Vac optional). The input power is 60 W for each pair of
fans.

CAUTION: a free circulation must be guaranteed for the air flow.

TAB. 1.15 - FANS.

MODEL INPUT PAIR CONFIGURATION

VOLTAGE OF
(V∼) FANS
DBM F2 230 1 DBM-PS + 1 DBM
DBM F3 230 1 DBM-PS + 2 DBM
DBM F4 230 2 DBM-PS + 3 DBM
DBM F5 230 3 DBM-PS + 4 DBM
DBM F2 (110V) 110 1 DBM-PS + 1 DBM
DBM F3 (110V) 110 1 DBM-PS + 2 DBM
DBM F4 (110V) 110 2 DBM-PS + 3 DBM
DBM F5 (110V) 110 3 DBM-PS + 4 DBM

Note: to size the fans a DBM-L (180 mm) module counts as two DBM modules.

Example: DBM-PS, one DBM module and one DBM-L (180 mm) module, requires a DBM F4
fan type.

1.11 Recovery Circuit

The recovery circuit is formed by a switching regulator, a recovery transistor and a recovery
resistance. While braking the motor returns energy which cannot be sent to the line since the
rectifier circuit is not regenerative. Returned energy tends to increase the BUS BAR DC
voltage. When HV reaches 375V the switching regulator brings the recovery transistor into
conduction, thus connecting the recovery resistance in parallel with filter capacitors. The
recovery resistance is formed by enameled wire fixed resistor(s).

37 - 6/July/98
If the recovery resistance works for intervals shorter than the time necessary to reach thermal
equilibrium, the resistor can temporarily handle power levels up to 10 times the nominal
power rating of the resistor (short time overload).

If not specifically requested, systems are provided with standard 3.9 Ω, 370W recovery
resistor.
An oversized Power Supply with three 8.2 Ω, 370 W (parallel configuration) is available.

WARNING: an unusual application with motor driven by the load, a large portion
of the time, could result in overheating of the recovery resistor.
An unusual application with motor driven by high inertial load from
high velocity in very short deceleration time could result in the
explosion of the input capacitor.
It is suggested contacting our Customer Service.

WARNING: do not touch recovery resistor during operation to avoid scalds.

Ventilated enclosures containing dynamic braking resistors shall
provide a degree of protection of at least IP22 (according to EN
60204-1, par. 13.3).

1.12 Standard Configurations

The modules are available in almost all combinations in the multiple version (see Fig.1.13A
and 1.13B).
We recommend to contact our Sales Locations or Service Centers for guidance on correct
selection of drives.

38 - 6/July/98
1.13 Block Diagrams
FIG. 1.15 - Power Supply, block diagram

39 - 6/July/98
FIG. 1.16 - Digital Section, block diagram

40 - 6/July/98
FIG. 1.17 - Analog Section, block diagram

41 - 6/July/98
Fig. 2.1 - Transformer Connections

230 VAC

42 - 6/July/98
Section 2 - Installation

2.1 Wiring

This section provides the necessary information to properly wiring the digital brushless
system.

1. Mains connections via transformer or autotransformer.

2. Resolver and motor power wiring.
3. Signals wiring.
4. Other wiring.

2.1.1 Mains Connections via Transformer or Autotransformer

Figure 2.1 shows the electric diagram for transformer or autotransformer connection (from
three-phase mains voltage to 230V). See Appendix D for a correct sizing.

If a transformer is used it is recommended to set the - HV to the ground, the secondary

neutral remaining floating. It is recommended to use star primary winding and delta
secondary winding.

If an autotrasformer is used, the -AT must not be connected to the ground.

REMARK: the auxiliary supply must be independent from the power supply, if the fault
information (see FA command) is to be retained in case of a mains failure.

43 - 6/July/98
Fig. 2.2 - Soft Start

44 - 6/July/98
2.1.2 Soft Start

Figure 2.2 shows a current limit circuit for a standard configuration (1 Power Supply and 3
modules): it is not strictly necessary for the system operation, though it is recommended to
limit the current through R-S-T phases on power up, as filter capacitors at power supply input
are uncharged and can require very high instantaneous current.

The three limit resistors must be short-circuited after 150 to 200 ms. They must be of high
energy type (to charge/uncharge capacitors) and must be rated 10 to 20 Ω, 100W.

The delay can be achieved by a timer (CR2 in Fig. 2.2) or by the circuit marked CR1 in
Fig. 2.2. In this case the component list is as follows:

Cc : capacitor 0.1 µF, 250V

Cd : electrolytic capacitor 20 µF, 250V
F1, F2 : fuse 315 mA,- 250V
K1 : bridge rectifier 1A, 400V
Rc : resistor 22 Ω, 5 W
Rd : resistor 10 kΩ, 5 W
T2 : relay SPST 5A, 220V, coil 110 V, 10 kΩ

45 - 6/July/98
FIG. 2.3 - Resolver Wiring

grounding of
shield via

grounding of shield
via connector clamp

46 - 6/July/98
2.1.3 Resolver Wiring

Each DBM module can be connected up to 3 resolvers via the following connectors:

J4 M1 : axis 1 resolver
J5 M2 : axis 2 resolver
J6 M3 : axis 3 resolver

A cable with 4 pair, each pair twisted and individually shielded with an independent overall
shield is recommended. 22 AWG ( 0.38mm2 ) to 20 AWG ( 0.6 mm2 ) can be used.

Resolver cables must be separated from power cables by a distance of 30cm (12 inches) by
using a independent duct (conduit). It is recommended to avoid intermediary connections for
resolver cables.

Figure 2.3 shows the wiring lay-out of the resolver with differential output.

2.1.3 Motor Power Wiring

There are seven different motor power connections, depending on module configuration (See
Fig. 1.12 and 1.13).

REMARK: motor power cables must be shielded.

2.1.5 Signals Wiring

All the enable signals and OK signals must be connected.

REMARK: it is suggested to connect the isolated output "DRIVE OK" to a remote control
switch so that, if a fault occurs, the power supply is disconnected to avoid system
damages.

2.1.5.1 Simulated Encoder Signals Wiring

Encoder signals cable must be shielded. For lengths in excess of 5 m (16 ft.) the cable must
have 3 pairs, each pair twisted.

REMARK: in noisy environments it is suggested to connect a 220 ÷ 680 Ω resistor between

A and A, B and B, C and C at the receiver input.

2.1.6 Serial Link Wiring

CAUTION: the serial link must be shielded and must be separated from the
power cable through the use of independent duct (conduit).

47 - 6/July/98
2.1.7 Serial Link Connection

REMARK: for the first installation it is strongly recommended to use either the
optional keypad or the DBTALK communication program.

2.1.7.1 Keypad

The keypad is an optional accessory product which can be used for drive setup and
monitoring. It must be connected to J10 connector.
If problems occur when attempting to communicate, the keypad is most likely set incorrectly.
To start the setup procedure press <CTRL>, then <CR>. For each parameter the current
setting is displayed, together with a question asking if you want to change it.
The correct setting is:
BAUD = 9600
WORD = 8D+E+1 STOP
BLOCK MODE
SINGLE LINE MODE
FLASHING OFF
KEY REPEAT ON SLOW

Be sure to save at the end of the procedure by pressing <Y> when the display shows: "Make
changes permanent Y/N".

2.1.7.2 DBTALK Communication Program

See Appendix B.

2.1.8 Other Wiring

• the braking resistor

• the flat cable for auxiliary supplies
• the keyboard (or PC)
• all the analog references

2.2 Installation

2.2.1 Starting Sequence

• Connect 230 Vac (or 110 Vac) single phase power supply.
• Multimodule configuration only. Disconnect the first module from the serial link and assign
basic address to the second module and so on for the next modules (all the modules from
factory being usually configured with address 1,2,3 if 3-axis or with address 1,2 if 2-axis).

Example of basic address assignment for the 2nd module, the first module being triple-axis:

FROM KEYBOARD (see Chapter 3 for a detailed description of commands)

1 SA 4 <CR> Assign basic address 4 to the second module (its primary axis)
4 SV <CR> Save the address configuration
48 - 6/July/98
Note: a module programmed as "address 4" will automatically assign for the other axes the
following addresses, i.e. 5 - 6 (if triple-axis) or 5 (if double-axis); and so on for the next basic
addresses.

• Check if NP (pole number), MV (max velocity) and MR (max reference) parameters are OK
for the application.

• Make a hardware reset via button on drive or via positive logic on pin 18 of J8 connector
(software reset via FA command being useless for digital control card reinitialization).

• Connect 230Vac three phase power supply.

WARNING: HIGH VOLTAGE - DISCHARGE TIME APPROX. 6 MINUTES.

2.2.2 "Keyboard" or "Opto" Priority

On the personality card there is a jumper (G2) (See Fig. 2.4) which gives priority to keyboard
or to opto to execute "Drive Enable" command. " Drive Enable" opto isolated signals are
connected to J8/ pos.13, 14, 15.

G2 opened (position 2-3) = keyboard priority = the keyboard (or the device connected to the
serial link) is the master, i.e. it allows to enable or disable motor current, whereas the
optocouplers can only disable (protection); they can enable after resetting only.

The "Drive Enable" and "Reference Enable" opto-isolated signals must be driven at +15V.

Such a procedure, should be followed during installation and drive test.

G2 closed (position 1-2) =opto priority =the optocouplers are the master and the keyboard
can only be used for parameters setup.

Note: "Drive Enable" priority is different from the use of the analog or digital reference.
You can choose an analog or digital reference by "AR" (Analog) or "DR" (Digital) commands,
and save. The drives are supplied set to digital reference "DR".

2.2.3 Autophasing

Note: it is possible to limit the current in autophasing via IL command.

• Check that the motor is free to rotate in both directions.

• Check that no fault condition occurs (red DRVF leds off).
•The jumper G2 on the personality card must be opened.
• Check that all module axes have analog drive enable on via positive logic and digital drive
enable off.
• Send the password command for the module.
• Send the autophasing command for every axis of the module and save.

49 - 6/July/98
Example for a double module with axis 4 and axis 5:

FROM KEYBOARD

4 PW91 <CR> Enter the password for 2nd module (primary axis = 4)
PASSWORD ON The correct answer is displayed
<CR> Only for optional keyboard.
4 AP <CR> Allow axis 4 autophasing.
AUTOPHASING IN PROGRESS
AXIS PHASED
5 AP <CR> Allow axis 5 autophasing.
AUTOPHASING IN PROGRESS
AXIS PHASED
4 SV <CR> Save module 4 phasing.

• Repeat the password and autophasing procedures for subsequent modules (if applicable).
• Make a hardware reset via button on drive or via positive logic on pin 18 of J8 connector.

2.2.4 Wiring Checks

After phasing each axis, it is possible to check the wiring by rotating the motor via its digital
reference.

• Enable analog Drive Enable and Reference Enable via positive logic.
• Check that G2 is in position 2-3, for keyboard priority.
• Send to every axis the ON command (to enable digital Drive Enable) , the VE command
(for CW slow rotation), the VE- command (for CCW slow rotation), the OF command (to
disable the digital Drive Enable).

Example of checking axis 5 rotation:

FROM KEYBOARD

5 ON <CR> Enable digital Drive Enable for axis 5

O Drive Enable led will be on
5 VE 50 <CR> Set CW rotation at 50 rpm
5 VE-50 <CR> Set CCW rotation at 50 rpm
5 OF <CR> Disable digital Drive Enable for axis 5
O Drive Enable led will be off

50 - 6/July/98
2.2.5 CNC Priority

With CNC, the following procedures must be followed. This way the CNC is the master and
the keyboard is the slave, as follows:

• Parameters managed by CNC: Drive Enable, Reference Enable, Speed References

• Parameters managed by keyboard (or PC): all dynamic parameters (acceleration, KI, KP,
etc.), Status and Fault.

2.2.5.1 Setting of Analog References

To set the modules to use the analog references from the CNC, it is necessary to enter the
password, to send the AR command to every axis and to save. ST command can be entered
to check if the commands have been accepted.

Note that:
• AR command can be sent via global address (∗).
• If there are two or more modules, PW (password) and SV (save) commands can be sent to
each module (not only to each axis).

Example of enabling all the analog references for two modules with axes 1,2,3 and 4,5:

FROM KEYBOARD

1 PW91 <CR> Enter the password for 1st module (primary axis= 1)
PASSWORD ON The correct answer is displayed
4 PW91 <CR> Enter the password for 2nd module (primary axis = 4)
PASSWORD ON The correct answer is displayed
* AR <CR> Enable analog reference for all axes
1 SV <CR> Save the configuration for 1st module
4 SV <CR> Save the configuration for 2nd module
1 ST <CR> Ask the status for axis 1
A1 ST___ E___ I_0___ Axis 1 status is displayed. Check the 0 in the 2nd bit
after I (bit i)
... Repeat ST command and check other axes

2.2.5.2 Drive Enable with CNC Priority

To give the priority for enabling and disabling the drive from the CNC, it is necessary to pull
out the personality card from the module, install G2 jumper in position 1-2 (closed) and to pull
in the card.

REMARK: if there are more than one module, do not swap the personality cards, this will
swap the module data.

51 - 6/July/98
2.2.6 Velocity Offset

If it is necessary you can adjust the analog velocity offset by providing 0 analog speed
reference and setting VO command for an automatic adjustment. A fine adjustment can be
done with successive steps via OV command.
REMARK: the adjustment of the digital velocity offset must not be used to adjust the analog
velocity offset and it is reserved to setup technicians. It can be made by providing 0 digital
speed reference (VE=0) and setting OC command. The opto Drive Enable must be high.

2.2.7 Personality Card Jumpers

WP (default: open): if closed, the EEPROM is write protected and SV command disabled
G1 (default: open) : if closed, connects TX- of serial link to 0V via pull-down resistor
G2 : if closed, gives priority to "opto" , if open gives priority to "keyboard"
G3 (default: open) : if closed, set 9600 Baud rate and basic address 1
G4 (default: open) : if closed, connects TX+ of serial link to 5V via pull-up resistor
G5 (default: open) : if closed, connects a 120 Ω resistor between RX+ and RX- of serial link

CAUTION: it is recommended to close the WP jumper at the end of installation

and setup.

Fig. 2.4 - Personality Card

Jumper open

Jumper closed

REMARK: personality card of DBM 03 has a software different from DBM 01 personality card.
To change DBM 01 with DBM 03:
1. Switch on DBM 03 with 230V mono-phase and replace the personality card with the old
DBM 01 personality card with G2 and G3 jumpers closed
2. Reset the drive with reset button on front panel
3. Wait 30 sec
4. Switch off the drive
5. Restore G2 and G3 as before the removal
The personality card is now set to DBM 03 format. New parameters are: 1SO=1; 2SO=2;
CU=128; CV=128; DF=0; ES=16; ET=80; PW=91, RN=RX=12; PR=3 and VS=0 for 2 pole
resolver; PR=1 and VS=1 for 6 pole resolver; SE=1024 (if applicable).
Note: - if the number of pulses per revolution has to be different from 1024, SE parameter
must be properly specified in the order
- after this setting the personality card cannot be used with DBM 01.
- with G2 and G3 closed DBM 03 does not work. The situation is as follows:
G2 open, G3 closed = keyboard priority, 9600 Baud, base address 1, password ON.
G2 and G3 closed = opto priority, reading of DBM 01 parameters (AC, AL/DL, AR/DR, BR, DE, IL,
IT, KI, KP, MR, MV, NP, OC, PC, RS, SA), password OFF.

52 - 6/July/98
2.2.8 Resolver to Encoder (optional)

For position sensing a resolver to encoder option (simulated encoder) is available.

Encoder signals are 7V, 100 Ω impedance, as follows:
• 2 channels of square wave output with a resolution from 128 to 1024 pulses per electrical
revolution. Channel B leads channel A by 90° for clockwise rotation when viewed from
shaft end.
• 1 marker pulse per electrical revolution (i.e. 1∗ 3 = 3 marker pulses per mechanical
revolution with a 6 pole resolver).
• complementary outputs A, B and C .

FIG. 2.5 - Simulated Encoder (CW rotation when viewed from shaft end)

C h a n n el A

Channel B

C M a rk e r

Channel A

Channel B

C M a rk e r

53 - 6/July/98
2.2.8.1 Setup for the Number of Steps/Revolution

From DBM 03 version the number of steps/electrical revolution of simulated encoder can be
set via software (see SE commands).

REMARK: the maximum number of pulses per electrical revolution depends on the R/D
resolution. See Tab.2.1.

The width of C marker can be A (360°), A/2 (180°) or A/4 (90°); it must be specified in the
order. This parameter does not depend on the software commands.

Note: to obtain the resolution per mechanical revolution it is necessary to multiply the pole
pairs by the electrical resolution.

Example: if a FAS T motor with 6 pole resolver is used, 1024 pulses per electrical revolution
mean 1024 ∗ 3 = 3072 pulses per mechanical revolution.

54 - 6/July/98
2.2.8.2 R/D Resolution

From DBM 03 version the resolution of Resolver to Digital converter will automatically be
switched according to actual speed for optimum system performance between minimum (see
RN command) and maximum resolution (see RX command).

The speed range of R/D resolution is included in the following table.

Tab. 2.1 - Max speed and max ppr versus R/D resolution

Resolution (bit)
10 12 14 16
Max number of pulses per 256 1024 4096 16384
electrical revolution

Max speed with 2 pole 24000 12000 3510 877

resolver (rpm)

Max speed with 6 pole 8000 4600 1170 292

resolver (rpm)

Max speed with 8 pole 6000 3510 877 219

resolver (rpm)

55 - 6/July/98
FIG. 2.6 - Starting Sequence, Timing Chart

Note: T1 = 8 to 10 s, T2 ≥ 1 s, T3 ≥ 20 ms, T4 ≈ 3 s, T5 ≥ 0.5 s.

230 Vac

230 Vac

56 - 6/July/98
2.3 Operation

After system wiring and installation, it is possible to start the system according to the
sequence shown in figure 2.6.

Action Effect

• Connect 230Vac single phase • Digital and diagnostics circuits

power supply (or 110Vac are fed
optional) - Green LED on DBM PS, AUX PWR = ON
- Opto output MOTOR OK is enabled

• Connect 230Vac three phase • 300V Bus Bars are fed

power supply - Yellow LED on DBM PS, PWR BUS = ON
- Green LED on DBM, POWER OK = ON

• Reset protections by pushing • Possible faults are reset

the RESET button on front - After 3s the opto output DRIVE OK is enabled
panel or by sending a 20ms
pulse to REM RESET opto input

• Enable analog Drive Enable • Green LED's on DBM, DRIVE EN = ON

for each axis and Reference and REF EN = ON
Enable via positive logic

WARNING: HIGH VOLTAGE - DISCHARGE TIME APPROX. 6 MINUTES.

57 - 6/July/98
SECTION 3 - COMMANDS AND PROTECTIONS

3.1 General Features

For serial communication, according to standard RS485, DBM drives are connected in
parallel (multidrop) and in "slave" configuration, whereas the CNC, the PC or the keyboard
are in "master" configuration.

This is because the protocol is configured so that the drives are able to communicate only if
inquired by the master, to avoid contentions on the line. As a consequence, all the
commands have been configured individually (single axis questioned), except those for which
an answer is not foreseen; therefore all the drives can be reached simultaneously.

There are 3 kinds of command:

• status monitoring
Monitor commands on the status of the drive, which displays axis configuration and eventual
faults.

• data monitoring
Monitor commands for displaying memorized motion parameters (e.g. I limit=100%, etc.).

• data (command) input

Execute commands for setting and changing parameters (e.g. speed, pole number,
acceleration, deceleration, etc.).

Remark: if a mistake has been made while digitizing, it is possible to reset the command by
pressing <CR> ( <CARRIAGE RETURN> ).

The commands are in ASCII format:

1 bit-start
8 bit-data
1 bit-parity even
1 bit-stop

Serial communication speed can vary from 1200 to 19200 Baud.

58 - 6/July/98
Command syntax is as follows:

status monitoring: „ address COMMAND

data monitoring: „ address COMMAND
data input: „ address COMMAND data
command input: „ address COMMAND

Remark: press <CR> after each command string if the optional keyboard is used.

• Address: there are three kinds of address:

Axis: it is a number from 1 to 9 ( max. number of axes in a system); it identifies the axis
selected for data monitoring / input.

Module: the "module" (or "basic") address is referred to the possibility to get the execution of
the command either addressing the chosen axis (axis) or any axis inside the module (
module ). This last possibility is valid for all axes within a module common commands (e.g.
temperature).

Global: it is also possible to globally address all axes (global address) using the <∗> in place
of the address number.

• Command: it consists of two letters (e.g. AC, AE, etc.).

• Datum: it can be composed by a max. of 4 figures or 3 figures and the <-> symbol. The
<+> symbol is optional. Any data without a symbol is considered as positive.

59 - 6/July/98
3.2 Commands

All commands available for system management can be used to monitor and execute every
datum.

To monitor, it is sufficient to enter the address and the command; to execute, the address,
the command and the datum must be typed.

Tab. 3.1 List of Commands

Symbol Command Symbol Command

AC Acceleration MV Max velocity
AD Axis disabled NP Number of poles
AE Axis enabled OC Velocity Fine offset
AL Analog limit OF Off
AP Autophasing ON On
AR Analog reference OV Offset Display
AS Address show PC Peak current
BR Baud rate PR Motor poles to
CP Current position resolver poles ratio
CU Current U offset PW Password
CV Current V offset RE A/D resolution
DE Deceleration RN Minimum of R/D
DF Digital velocity resolution
reference filter RS Resolver shaft
DI Direction RX Maximum of R/D
DL Digital limit resolution
DR Digital reference SA Set Address
ES Extra parameter SE Simulated encoder
for spare output SO Spare output
ET Extra parameter SR Show Release
for Tacho output ST Status
EV Error velocity SV Save
FA Fault TC Torque Control
IL I Limit VC Velocity Control
IT IT protection VE Velocity
KI Integral gain VO Velocity Offset
KP Proportional gain VS Velocity structure
MR Max reference

60 - 6/July/98
3.2.1 Command: AC - Acceleration

Function: it allows to set an acceleration ramp. Whatever the input

reference (analog or digital), the system will follow it, but
accelerations will never be faster than those set by this command. It
can be useful when the drive is connected to rather simple position
controllers ( e.g. max, 0, -max), with an application requiring
progressive accelerations.
Syntax: data monitoring: „ address AC <CR>
data input: „ address AC n <CR>
Address type: axis
Unit of measure: n = ms
Range: 10 to 999 or 0
Default: 0 (disabled)
Password: no
(∗) addressing: yes
Opposite to: -
See also: DE

Examples:
„ 1 AC 100 <CR>: it sets an acceleration ramp = 100ms for axis1.
„ 2 AC <CR>: it questions axis 2 about the acceleration ramp. In case no one has been set, the
answer is: "A2 ACC. TIME = ms 0".

FIG. 3.1 - Acceleration/Deceleration

rpm

MV

VE DE

AC ms

DE AC

61 - 6/July/98
3.2.2 Command: AD - Axis Disabled

Function: AD command makes the logic section ignore an axis and the
relatives faults. It is useful with DBM 2-axis: if the
third axis were not disabled, the logic would reveal resolver
fault and motor overtemperature, preventing the drive from
running.
Syntax: data monitoring: „ address AD <CR>
data input: „ address AD n <CR>
Address type: axis
Unit of measure: n = axis number
Range: 1 to 99
Default: -
Password: yes
(∗) addressing: no
Opposite to: AE
See also: AE

Note: the axis disabled holds his address, which can be interrogated via FA command.

REMARK: AD and AE commands must be set only when the motor is standstill

Examples:
„ 1 AD 3 <CR>: it disables the 3rd axis of a module, whose first address is 1.
„ 4 AD 6 <CR>: it disables the 3rd axis of a module, whose first address is 4.
„ 1 AD <CR>: "1 AXIS DISABLED 3" will be displayed if the 3rd axis is disabled. "1 AXIS DISABLED 1 3"
will be displayed if the 1st and 3rd axis is disabled.

3.2.3 Command: AE - Axis Enabled

Function: the AE command enables an axis and relative faults.

Syntax: data monitoring: „ address AE <CR>
data input: „ address AE n <CR>
Address type: axis
Unit of measure: n = axis number
Range: 1 to 99
Default: -
Password: yes
(∗) addressing: no
Opposite to: AD
See also: AD

Examples:
„ 1 AE 3 <CR>: it enables the 3rd axis of a module, whose first address is 1.
„ 4 AE 6 <CR>: it enables the 3rd axis of a module, whose first address is 4.
„ 1 AE <CR>: "1 AXIS ENABLED 3" will be displayed if the 3rd axis is enabled. "1 AXIS ENABLED 1 3"
will be displayed if the 1st and 3rd axis is enabled.

62 - 6/July/98
3.2.4 Command: AL - Analog Limit

Function: it informs the controller that I limit reference to be considered is

analog (see J7 connector).
Syntax: command input: „ address AL <CR>
Address type: axis
Unit of measure: -
Range: -
Default: digital I Limit
Password: yes
(∗) addressing: yes
Opposite to: DL
See also: DL, IL, ST

Examples:
„ 1 AL <CR>: Sets the analog I limit for axis 1. The display is cleared. After this command a current
limit can be set via J7 connector, pos. 14 and 33 (range 0 to 10V).
The status can be interrogated via ST command.

REMARK: DBM 03 has the "Analog I limit" as standard.

3.2.5 Command: AP - Autophasing

Function: AP command allows resolver auto-phasing. As in this phase the

motor can rotate for a revolution fraction, it is opportune to make
sure it is free to rotate to avoid risk of friction, which could
compromise phasing accuracy. So, motor must be disconnected
from load.
Syntax: command input: „ address AP <CR>
Address type: axis
Unit of measure: -
Range: -
Default: non-phased axes
Password: yes
(∗) addressing: no
Opposite to: -
See also: ON, OF

Note: To execute AP, all module axes must have optoisolated Drive Enable signals "on" and digital ones "off"
(see paragraph 2.2.3) via OF command. To execute AP, it is necessary that the "G2" jumper on the
personality card is in position 2-3 (open), which means priority from the keyboard (see paragraph 2.2.2.).

Examples:
„ 1 AP <CR>: it allows axis 1 auto-phasing. During such operation (a few seconds) "AUTOPHASING IN
PROGRESS" will be displayed; when auto-phasing is successfully carried out "AXIS PHASED" will be
displayed, otherwise "ERROR IN AUTOPHASING" will be shown. If digital Drive Enable is enabled (ON) (see
above) the message "WARNING DRIVE EN. CLOSED" will appear. The auto-phasing is not allowed if a
fault is on. This case, the message displayed will be "ERROR: FAULT STATUS".

63 - 6/July/98
3.2.6 Command: AR - Analog Reference

Function: AR command allows enabling analog (speed or torque) reference.

pins, ignoring VE command given from keyboard.
Syntax: command input: „ address AR <CR>
Address type: axis
Unit of measure: -
Range: -
Default: digital reference
Password: yes
(∗) addressing: yes
Opposite to: DR
See also: DR

Note: the status can be interrogated via ST command (bit I).

3.2.7 Command: AS - Address Show

Function: it allows display of the basic address of a module, if unknown. To

avoid simultaneous answers on the line from more than one
module, it is necessary that serial flat J2 is connected only between
power supply and the questioned module. It is different from
SA command, which is used to change basic address.
Syntax: data monitoring: „ ∗ AS <CR>
Address type: -
Unit of measure: -
Range: -
Default: -
Password: no
(∗) addressing: compulsory
Opposite to: -
See also: SA

Examples:
„ ∗ AS <CR>: if the "base" address for such a module is 1, the answer will be "ADDRESS MODULE 1".

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3.2.8 Command: BR - Baud Rate

Function: it allows to change transmission speed of the serial link.

Syntax: data monitoring: „ address BR <CR>
data input: „ address BR n <CR>
Address type: module
Unit of measure: n = Baud
Range: 1200, 2400, 4800, 9600, 19200
Default: 9600
Password: yes
(∗) addressing: yes
Opposite to: -
See also: -

Note: To modify the Baud Rate alsoat keyboard side, it is necessary to type <Control> and after <CR>.
Type <Y> to change Baud Rate and after <CR>.

3.2.9 Command: CP - Current Position

Function: it allows to know the position relative to electric revolution of the

resolver at start-up. It is used when the application requires to
know the absolute position.
Syntax: data monitoring: „ address CP <CR>
Address type: axis
Unit of measure: -
Range: 0 to 4096
Default: -
Password: no
(∗) addressing: no
Opposite to: -
See also: -

Examples:
„ 2 CP <CR>: Interrogates axis 2 about the current position. If the starting position is 4006, the
answer will be : "A02 CURRENT POSITION = 4006".

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3.2.10 Command: CU - Current U offset (only for setup technicians)

Function: it allows to set the offset of U phase current

Syntax: data monitoring: „ address CU <CR>
data input: „ address CU n <CR>
Address type: axis
Unit of measure:
Range: 0 to 255
Default: -
Password: no
(∗) addressing: no
Opposite to: -
See also: CV

Note: the CU command must be executed with digital Drive Enable disabled (via OF command) and the opto
Drive Enable enabled.

Examples:
„ 2 CU <CR>: Interrogates axis 2 about the offset of the U current. If U current offset is 128, the
answer will be : "A02 CURRENT U OFFSET = 128".

CAUTION: do not change CU parameter. A wrong set of CU increases torque ripple.

3.2.11 Command: CV - Current V offset (only for setup technicians)

Function: it allows to set the offset of V phase current

Syntax: data monitoring: „ address CV <CR>
data input: „ address CV n <CR>
Address type: axis
Unit of measure:
Range: 0 to 255
Default: -
Password: no
(∗) addressing: no
Opposite to: -
See also: CU

Note: the CV command must be executed with digital Drive Enable disabled (via OF command) and the opto
Drive Enable enabled.

Examples:
„ 1 CV <CR>: Interrogates axis 1 about the offset of the V current. If V current offset is 128, the
answer will be : "A01 CURRENT V OFFSET = 128".

CAUTION: do not change CV parameter. A wrong set of CU increases torque ripple.

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3.2.12 Command: DE - Deceleration

Function: it allows to set a deceleration ramp. Whatever the input reference

(analog or digital), the system will follow it, but deceleration's will
never be faster than those set by this command. It can be
useful when the drive is connected to a rather simple position
controller (e.g. max,0,-max), with an application requiring
progressive deceleration's (see Fig. 3.1).
Syntax: data monitoring: „ address DE <CR>
data input: „ address DE n <CR>
Address type: axis
Unit of measure: n = ms
Range: 10 to 999 or 0
Default: 0 (disabled)
Password: no
(∗) addressing: yes
Opposite to: -
See also: AC

Examples:
„ 1 DE 100 <CR>: it sets a deceleration ramp = 100 ms for axis 1.
„ 1 DE <CR>: it questions axis 1 about the deceleration ramp. In case no one has been set, the
answer is: "A01 DECEL. TIME = ms 0"

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3.2.13 Command: DF - Digital Filter

Function: it allows to set a low-pass digital filter. The filter reduces high
frequency noise and resonance's
When the Velocity Structure command is VS=0 or VS=1, the
velocity reference is filtered.
When the Velocity Structure command is VS=2 or VS=3, the
velocity error is filtered.
The value DF=0 switches the filter OFF
Syntax: data monitoring: „ address DF <CR>
data input: „ address DF n <CR>
Address type: axis
Unit of measure: -
Range: 0 to 255. The filter bandwidth is:
f [Hz] = {ln[1/(1-DF/512)]}/(2π∗300 10-6)
Default: 0 (disabled)
Password: yes
(∗) addressing: no
Opposite to: -
See also: VS

Note: the DF command must be executed with digital Drive Enable disabled (via OF command) and the opto
Drive Enable enabled.

Examples:
„ 2 DF 165 <CR>: sets the filter bandwidth to 206 Hz for axis 2.
„ 2 DF <CR>: Interrogates axis 2 about the reference filter on the velocity reference. The answer will
be : "A02 DIG.FIL. REF. PAR. = 165".

Tab. 3.2 - Filter Bandwidth

DF Frequency DF Frequency DF Frequency DF Frequency

1 1 Hz 65 72 Hz 130 155 Hz 195 254 Hz
5 5 Hz 70 77 Hz 135 162 Hz 200 262 Hz
10 10 Hz 75 84 Hz 140 169 Hz 205 271 Hz
15 15 Hz 80 90 Hz 145 176 Hz 210 280 Hz
20 21 Hz 85 96 Hz 150 183 Hz 215 288 Hz
25 26 Hz 90 102 Hz 155 191 Hz 220 297 Hz
30 32 Hz 95 108 Hz 160 198 Hz 225 307 Hz
35 37 Hz 100 115 Hz 165 206 Hz 230 316 Hz
40 43 Hz 105 121 Hz 170 214 Hz 235 325 Hz
45 48 Hz 110 128 Hz 175 221 Hz 240 335 Hz
50 54 Hz 115 134 Hz 180 229 Hz 245 345 Hz
55 60 Hz 120 141 Hz 185 237 Hz 250 355 Hz
60 66 Hz 125 148 Hz 190 246 Hz 255 366 Hz

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3.2.14 Command: DI - Direction

Function: it allows to invert the direction of the motor rotation, in case of

analog or digital reference. The drive is supplied set to CW
rotation, (viewed from shaft end) corresponding to positive
during the installation. To know what the actual configuration is,
ST command shall be asked.
Syntax: command input: „ address DI <CR>
Address type: axis
Unit of measure: -
Range: -
Default: CW
Password: no
(∗) addressing: yes
Opposite to: -
See also: ST

Example:
„ 4 DI <CR>: it reverses the direction of motor rotation for axis 4. The display is cleared.

Note: The status can be interrogated via ST command (bit L).

3.2.15 Command: DL - Digital Limit

Function: it informs the controller that the I limit reference to be considered as

active is digital (programmable via IL command).
Syntax: command input: „ address DL <CR>
Address type: axis
Unit of measure: -
Range: -
Default: digital I limit
Password: yes
(∗) addressing: yes
Opposite to: AL
See also: AL, IL

Notes: Digital I limit is standard on DBM drives, whereas analog I limit is optional.
The status can be interrogated via ST command (bit J).

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3.2.16 Command: DR - Digital Reference

Function: it allows to enable digital (speed or torque) reference. The drive

will consider as reference the number set via VE command and
ignore connector J7 voltage.
Syntax: command input: „ address DR <CR>
Address type: axis
Unit of measure: -
Range: -
Default: digital reference
Password: yes
(∗) addressing: yes
Opposite to: AR
See also: AR

Note: the status can be interrogated via ST command (bit I)

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3.2.17 Command: ES - Extra parameter for Spare output

Function: it allows to scale the Analog Outputs (max current, speed reference
or error reference) on J8 connector.
Syntax: data monitoring: „ address ES <CR>
data input: „ address ES n <CR>
Address type: 1=Analog Output 1 (see J8 connector, pos.4)
2=Analog Output 2 (see J8 connector, pos.5)
Unit of measure: -
Range: 0 to 255. Analog outputs on J8 connector (±10V, 10 mA max):
Max current for axis 1 (SO=1), axis 2 (SO=2) or axis 3 (SO=3):
±(10∗ES/16)V for ±100% max current
Speed reference for axis 1 (SO=4), axis 2 (SO=5) or axis 3 (SO=6),
and velocity error for axis 1 (SO=7), axis 2 (SO=8) or axis 3 (SO=9):
±[(ES∗NP∗MV)/(786∗MR)]V for ±MV (max velocity)
Default: 16
Password: yes
(∗) addressing: no
Opposite to: -
See also: MR, MV, NP, SO

Examples:
„ 1 SO 1 <CR>: sets analog out1 (J8 conn., pos.4) to max current of axis 1
„ 1 ES 16 <CR>: sets analog out1 to ±10V for ±100% max current of axis 1
„ 1 ES 32 <CR>: sets analog out1 to ±10V for ±50% max current (zoom-in) of axis 1
„ 1 ES 8 <CR>: sets analog out1 to ±5V for ±100% max current (zoom-out) of axis 1
„ 2 SO 5 <CR>: sets analog out2 (J8 conn., pos.5) to speed reference of axis 2
„ 2 ES 16 <CR>: sets analog out2 to ±10V for ±6140 rpm (if NP=8 and MR=100 have been set for axis 2)

Tab. 3.3 - ES for Max Current (SO=1 to SO=3)

ES MAX ANALOG
CURRENT OUT
8 100 % 5V
16 100 % 10 V
32 50 % 10 V

Tab. 3.4 - ES for Speed Reference and Velocity Error (MR=100, SO=4 to SO=9)

2 pole resolver 6 pole resolver 8 pole resolver

ES MV ANALOG ES MV ANALOG ES MV ANALOG

rpm OUT rpm OUT rpm OUT
52 6046 8V 17 6165 8V 13 6046 8V
65 6046 10 V 22 5954 10 V 16 6140 10 V
105 2994 8V 35 2994 8V 26 3023 8V
131 3000 10 V 44 2977 10 V 33 2977 10 V
52 2015 8V 39 2015 8V
65 2015 10 V 49 2005 10 V

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3.2.18 Command: ET - Extra parameter for Tacho output

Function: it allows to scale the Tacho Tests outputs on J8 connector

Syntax: data monitoring: „ address ET <CR>
data input: „ address ET n <CR>
Address type: axis
Unit of measure: -
Range: 50 to 100. Tacho outputs = ±(ET/10) ∗ (MR/100) [V] for ±MV
Default: 80
Password: yes
(∗) addressing: no
Opposite to: -
See also: MR, MV

Examples:
„ 1 MV 3000 <CR>: sets max velocity to 3000 rpm for axis 1.
„ 1 MR 100 <CR>: sets max velocity reference to 10 V for axis 1.
„ 1 ET 50 <CR>: sets ET parameter to 50 for axis 1. The Tacho Test 1 (J8, pos.1) will be ± 5V for
± 3000 rpm.
„ 1 ET <CR>: questions axis 1 about the extra parameter for Tacho Test 1. The answer is: "A01 EXTRA
PAR. FOR TO = 50".

3.2.19 Command: EV - Error Velocity

Function: it allows to set the maximum velocity error between reference

velocity and the actual speed in rpm. If the set value is overcome,
a fault occurs. Value = 0 disables the command.
Syntax: data monitoring: „ address EV <CR>
data input: „ address EV n <CR>
Address type: axis
Unit of measure: n = rpm
Range: 1 to MV. 0 = disabled
Default: 0
Password: yes
(∗) addressing: no
Opposite to: -
See also: -

Remark: While testing the drives via step response, it is advisable to disable this protection or set a
high value of tolerated error, to avoid continuous faults.

Examples:
„ 1 EV 100 <CR>: it sets axis 1 to tolerate up to 100 rpm error, without fault.
„ 3 EV <CR>: it questions axis 3 about the maximum error allowed. The answer is: "A3 VELOCITY
ERROR RPM = 20" (if 20 rpm velocity error has been set for axis 3).

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3.2.20 Command: FA - Fault

Function: as only main faults have front panel LED indications, when the
generic LED DRVF lights up, it is necessary to interrogate
the drive via FA command. The answer is a codified ASCII string
(see below). Another function of the command is to reset the faults
Syntax: status monitoring and reset: „ address FA <CR>
Address type: axis
Password: no
(∗) addressing: no

Answer explanation: A a FA b c d e f g P h i j k l MA m n o B p q r

A = axis
a = axis address

FA = fault
b = Resolver connection 0 = OK 1 = not OK
c = Motor temperature 0 = OK 1 = overtemperature
d = Axis short circuit 0 = OK 1 = short circuit
e = 3-phase sequence 0 = OK 1 = not coherent phase
f = Velocity error 0 = OK 1 = not OK
g = It 0 = off 1 = on

P = Power supply
h = Recovery unit 0 = OK 1 = not OK
i = PWRS temperature 0 = OK 1 = overtemperature
j = 220Vac 3-phase sequence 0 = OK 1 = unbalanced phase
k = n.c.
l = Personality card 0 = OK 1 = not OK*

MA = A module (DBM module)

m = BUS BAR voltage 0 = OK 1 = overvoltage/undervoltage
n = Aux. Volt. ref. to - HV 0 = OK 1 = out of tolerance
o = A module temperature 0 = OK 1 = overtemperature

B = B module (eventual expansion module)

p = BUS BAR voltage 0 = OK 1 = overvoltage/undervoltage
q = Aux. Volt. ref. to - HV 0 = OK 1 = out of tolerance
r = B module temperature 0 = OK 1 = overtemperature

* = in case of checksum error, check the parameters (e.g. KP, KI,...), correct the wrong values and save.

Note: If the expansion missing, the last characters are not significant.

Examples:
„ 1 FA <CR>: if OK, the answer will be: "A1 FA 000000 P 00000 MA 000 B 000"

73 - 6/July/98
3.2.21 Command: IL - I Limit (Current Limit)

Function: it allows to program the peak current. It is useful when

undersized motors are used or during special tests.
Syntax: data monitoring: „ address IL <CR>
data input: „ address IL n <CR>
Address type: axis
Unit of measure: n = % max current
Range: 0 to 100
Default: 100
Password: no
(∗) addressing: no
Opposite to: -
See also: DL, AL

REMARK: before executing IL command it is necessary to perform DL command.

Examples:
„ 2 IL <CR>: it asks axis 2 about I limit. In default case the answer will be: "A2 CURRENT LIMIT % =
100".
„ 2 IL 90 <CR>: it sets 90% current limit for axis 2.

3.2.22 Command: IT - IT protection

Function: it allows to manage the IT thermal protections which prevents the

motor from an overheating too quick for the PTC operating
time. When the integral of current multiplied by time exceeds the
IT value, drive limits, after operating time, to nominal motor
current (see Tab. 3.5).
Syntax: data monitoring: „ address IT <CR>
data input: „ address IT xx n <CR>. xx = special password
Address type: axis
Unit of measure: n = ms
Range: 0 to 255. 0 = protection disabled
Default: see Tab. 3.5
Password: special password
(∗) addressing: no
Opposite to: -
See also: PC

Notes: IT protections has been implemented from software version 3.5.

IT status can be interrogated via FA command (bit g).

CAUTION: do not change IT parameter. A wrong set of IT can damage the motor.

74 - 6/July/98
Tab. 3.5 - IT Protection
The following table shows IT and PC values set in factory.

MOTOR DRIVE Operating MOTOR DRIVE Operating time

time at drive at drive peak
peak current current
DBM03 IT PC (s) DBM03 IT PC (s)
FAS T0 FAS K0
M2 030 1.5 15 24 7.0 005 030 1.5 11 23 8.8
M2 060 1.5 14 38 19.8 " 2.5 11 15 3.7
" 2.5 14 25 8.2 005 060 1.5 12 37 21.8
M4 030 1.5 16 40 19.4 " 2.5 12 25 9.6

" 2.5 16 27 8.4 010 030 1.5 14 40 22.2

M4 060 2.5 12 46 35.3 " 2.5 14 27 9.6
" 5 11 23 8.8 010 060 2.5 14 48 33.3
M8 030 2.5 12 44 31.9 " 5 11 24 9.6
" 5 11 22 8.0 020 030 5 13 26 9.6
M8 060 5 15 42 23 020 060 5 12 48 38.8
" 10 14 25 8.2 " 10 12 29 13.0
FAS T1 FAS K1
M2 030 2.5 9 55 71.3 020 030 2.5 6 48 77.8
" 5 8 27 16.9 " 5 5 24 21.2
M2 060 5 9 54 68.2 020 060 5 6 44 63.9
" 10 8 32 24.1 040 030 5 6 44 63.9
M4 030 5 7 49 69.9 " 10 6 26 20.8
" 10 7 30 24.0 040 045 10 6 40 51.8
M4 045 10 7 44 54.8 060 030 10 6 40 51.8
M6 030 10 4 42 86.6 " 15 5 22 17.7
" 15 4 23 24.2 060 045 10 6 60 132.6
M6 045 10 5 62 173.1 " 15 6 34 36.5
" 15 4 35 58.3 " 25 6 22 14.7
M8 030 10 5 52 112.5 080 030 10 6 53 98.0
" 15 4 29 39.2 " 15 5 29 31.3
M8 045 15 4 41 82.1 080 045 15 6 44 63.9
FAS T2 " 25 6 28 24.3
M2 030 10 8 52 70.2 FAS K2
" 15 8 29 19.6 060 030 10 5 43 72.9
M2 045 15 9 47 49.4 " 15 5 24 21.2
" 25 8 30 21.0 060 045 10 5 60 159.2
M4 020 10 7 59 109.0 " 15 5 33 41.1
M4 030 15 7 50 73.3 120 020 10 5 53 117.6
" 25 6 32 32.1 " 15 5 30 33.6
M6 020 15 6 48 77.8 120 030 15 5 44 76.8
" 25 5 30 33.6 " 25 5 29 31.3
M6 030 25 7 45 57.6 180 020 15 5 38 55.6
M8 020 25 6 39 49.0 180 030 25 5 43 72.9
M8 030 25 6 55 107.1 240 020 25 5 43 72.9
FAS T3 240 030 50 5 29 31.3
M2 020 25 6 48 77.8 FAS K3
M2 030 25 8 70 150.0 240 020 25 3 38 92.8
M3 020 25 6 64 156.6 240 030 50 3 27 45.0
M3 030 50 5 48 93.4 360 020 50 3 30 56.1
M4 020 50 4 40 77.8 360 030 50 3 44 128.0
M4 030 50 6 70 200.1 " 70 3 34 73.1
" 70 5 55 128.5 480 020 50 3 38 92.8
M6 012 25 5 66 204.0 " 70 3 30 56.1
M6 020 50 4 53 147.1 480 030 70 3 41 109.5
" 70 4 42 86.6 " 80 3 31 60.1
M8 012 50 4 42 86.6 720 012 50 3 33 68.6
M8 020 70 4 65 244.9 720 020 70 3 41 109.5
" 80 4 48 116.8 " 80 3 31 60.1
960 012 50 3 44 128.0
" 70 3 34 73.1
" 80 3 25 38.4
960 020 70 3 51 179.2
" 80 3 38 92.8
REMARK: the "operating time at drive peak current" is the operating time after a reset. In a steady state condition, this time can be shorter
according to the motor thermal simulation. An overtemperature protection via PTC is also provided.

75 - 6/July/98
3.2.23 Command: KI - Integral Gain

Function: it allows to set the speed loop integral gain. KI value is directly
proportional to the intensity of the integral action.
Syntax: data monitoring: „ address KI <CR>
data input: „ address KI n <CR>
Address type: axis
Unit of measure: -
Range: 0 to 255
Default: 20
Password: no
(∗) addressing: yes
Opposite to: -
See also: KP

Examples:
„ 2 KI <CR>: it asks axis 2 about KI. If it is 40, the answer will be "A4 KI = 40".
„ 2 KI 50 <CR>: it sets the integral gain to 50 for axis 2

3.2.24 Command: KP - Proportional Gain

Function: it allows to set the speed loop error proportional correction gain. KI
value is directly proportional to the intensity of the requested action.
Syntax: data monitoring: „ address KP <CR>
data input: „ address KP n <CR>
Address type: axis
Unit of measure: -
Range: 0 to 255
Default: 80
Password: no
(∗) addressing: yes
Opposite to: -
See also: KI

Examples:
„ 4 KI <CR>: it asks axis 4 about KP. If it is 90 the answer will be "A04 KI = 90".
„ 4 KI 50 <CR>: it sets the integral gain to 100 for axis 4.

76 - 6/July/98
3.2.25 Command: MR - Max Reference

Function: it allows to set speed/torque max reference. The drive will

automatically make it corresponding to the maximum velocity
(see MV command). It is advisable to set MR as near as possible
conversion.
Syntax: data monitoring: „ address MR <CR>
data input: „ address MR n <CR>
Address type: axis
Unit of measure: n = Volt decimal
Range: 50 to 100
Default: 100
Password: yes
(∗) addressing: no
Opposite to: -
See also: MV

Examples:
„ 1 MV 2000 <CR>:
„ 1 MR 100 <CR>: for axis 1, 10V correspond to 2000 rpm.
„ 3 MR <CR>: it interrogates axis 3 about max. reference. If MR = 10V the answer will be: "A3 MAX
REFER. V = 10.0"

REMARK'S: MR command can be executed only after resetting or giving MV command.

In case of torque control, it must be MR = 100.

77 - 6/July/98
3.2.26 Command: MV - Max Velocity

Function: it allows to set max velocity, referred to MR command. Anyway,

such a max. speed can never be overcome, either by analog
reference or by keyboard command.
Syntax: data monitoring: „ address MV <CR>
data input: „ address MV n <CR>
Address type: axis
Unit of measure: n = rpm
Range: 200 to 32000
Default: 3000
Password: yes
(∗) addressing: yes
Opposite to: -
See also: MR, Tab. 2.1

REMARK: max velocity depends on R/D resolution. See Tab. 2.1.

Examples:
„ 1 MV 2000 <CR>: sets max velocity for axis 1 to 2000 rpm.
„ 1 MR 100 <CR>: for axis 1, 10V correspond to 2000 rpm.
„ 1 MV <CR>: interrogates axis 1 about max. velocity. The answer will be: "A1 RPM MAX = 2000"

3.2.27 Command: NP - Number of Resolver Poles

Function: it informs the controller about the number of poles, so that

the right correspondence between mechanical speed and
electrical frequency can be set.
Syntax: data monitoring: „ address NP <CR>
data input: „ address NP n <CR>
Address type: axis
Unit of measure: -
Range: 2 to 8
Default: -
Password: yes
(∗) addressing: yes
Opposite to: -
See also: PR

Examples:
„ 1 NP 2 <CR>: allows to set 2 poles for axis 1.
„ 1 NP <CR>: allows to know the resolver pole number for axis 1. The answer will be: "A1 NUM. OF
POLES = 2"

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3.2.28 Command: OC - Digital Offset Compensation (only for setup technicians)

Function: it allows to set the digital velocity offset

Syntax: data monitoring: „ address OC <CR>
data input: „ address OC n <CR>
Address type: axis
Unit of measure: (n-128) ∗ x / 128 rpm
where x=24 for 8 and 2 pole resolver
x=32 for 6 pole resolver
Range: 0 to 255. OC = 128 disables offset
OC > 128 sets CW offset
OC < 128 sets CCW offset
Default: 128
Password: no
(∗) addressing: yes
Opposite to: -
See also: VO

Note: OC command has replaced KD command from software version 3.2.

Examples:
„ 1 OC 8 <CR>: adjust 30 rpm CCW offset for axis 1 with 6 pole resolver.
„ 4 OC <CR>: if OC = 90, the answer will be "A4 OC = 90".

3.2.29 Command: OF - Off

Function: it allows to disable the digital Drive Enable for the addressed axis
(see Par. 2.2.2.)
Syntax: command input: „ address OF <CR>
Address type: axis
Unit of measure: -
Range: -
Default: digital Drive Enable off
Password: no
(∗) addressing: yes
Opposite to: ON
See also: ON

REMARK: if opto Drive Enable are not enabled, the following message will be displayed: "ERROR:
DRIVE EN. OPEN". If the axis is not phased "AXIS NOT PHASED" will appear. If the jumper G2
is in position 1-2 (closed) the message "NOT POSSIBLE" will appear.

79 - 6/July/98
3.2.30 Command: ON - On

Function: it allows to enable the digital Drive Enable for the addressed axis
(see Par. 2.2.2.)
Syntax: command input: „ address ON <CR>
Address type: axis
Unit of measure: -
Range: -
Default: Digital Drive Enable off
Password: no
(∗) addressing: yes
Opposite to: OF
See also: OF

REMARK: if opto Drive Enable are not enabled, the following message will be displayed: "ERROR:
DRIVE EN. OPEN". If the axis is not phased "AXIS NOT PHASED" will appear. If the jumper G2
is in position 1-2 (closed) the message "NOT POSSIBLE" will appear.

3.2.31 Command: OV - Analog Offset

Function: it allows to monitor and to set the analog offset of speed/ torque
analog reference.
A fine adjustment of the analog offset can be done with successive
steps by setting and monitoring the OV parameter.
Syntax: data monitoring: „ address OV <CR>
data input: „ address OV n <CR>
Address type: axis
Unit of measure: -
Range: 0 to 255
Default: 128
Password: yes
(∗) addressing: no
Opposite to: -
See also: VO

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3.2.32 Command: PC - Peak Current

Function: it informs the drive control section about the ratio between motor
current and drive peak RMS current. This way, when IT protection
is
on, drive current will be reduced to nominal motor current.
Syntax: data monitoring: „ address PC <CR>
data input: „ address PC xx n <CR>. xx = special password
Address type: axis
Unit of measure: n=%
Range: 0 to 100
Default: see Tab. 3.5
Password: special password
(∗) addressing: no
Opposite to: -
See also: IT

CAUTION: do not change PC parameter. A wrong set of PC can damage the motor.

3.2.33 Command: PR - Motor Poles to resolver poles Ratio

Function: it allows to set the ratio between the motor pole number and the
resolver pole number.
Syntax: data monitoring: „ address PR <CR>
data input: „ address PR n <CR>
Address type: axis
Unit of measure: -
Range: 1 to 24
Default: -
Password: yes
(∗) addressing: no
Opposite to: -
See also: NP

Examples:
„ 2 PR 3 <CR>: sets axis 2 for 6 pole motor and 2 pole resolver
„ 2 PR <CR>: questions axis 2 about the ratio between motor poles and resolver pole number. The
answer is: "A02 MOTOR/RES. POLES = 3".

CAUTION: a wrong set of PR can damage the motor.

81 - 6/July/98
3.2.34 Command: PW - Password

Function: it allows the operator to change critical parameters. After executing

PW command, it is possible to enter the status in which such
modification are permitted. If you want to exit from this mode, set
PW again.
The DBM 03 release allows to change the password.
Syntax: command input: „ address PW n <CR>
data input: „ address PW n <CR>
Address type: module
Unit of measure: -
Range: 1 to 255
Default: PW91
Password: -
(∗) addressing: yes
Opposite to: -
See also: -

Examples:
„ 1 PW91 <CR>: if previously OFF, the answer is "PASSWORD ON"
„ 1 PW137 <CR>: enters a new password. The answer is "NEW PASSWORD IS 137 SAVE? "
„ 1 SV <CR> saves the new password. Note that all new parameters will be saved, if changed.
„ 1 PW137 <CR>: the answer is be "PASSWORD OFF"

CAUTION: Password protected parameters must be set only when the motor is standstill.

3.2.35 Command: RE - A/D REsolution

Function: it allows to display the resolution of A/D converter

Syntax: data monitoring: „ address RE <CR>
Address type: module
Unit of measure: bit
Range: 12 (standard) , 14 (optional)
Default: -
Password: no
(∗) addressing: no
Opposite to: -
See also: -

Example:
„ 1 RE <CR>: it questions module 1 about the resolution of A/D converter. The standard answer is: "12
BIT A/D CONVERTER IS PRESENT".

REMARK: the 14 bit A/D resolution is an option (CG5504 code). We recommend to contact
the Service Centers to restore the 12 bit resolution from the optional 14 bit resolution.

82 - 6/July/98
3.2.36 Command: RN - Minimum of R/D resolution

Function: it allows to set the minimum of Resolver to Digital converter

resolution. The R/D resolution will automatically be switched
according to actual speed for optimum system performance
between RN (minimum) and RX (maximum).
RN must be the maximum R/D resolution according to max speed
(see Tab. 3.6)
If RN equals RX, the R/D resolution is fixed.
Syntax: data monitoring: „ address RN <CR>
data input: „ address RN n <CR>
Address type: axis
Unit of measure: bit
Range: 10, 12, 14 and 16 (it must be ≤ RX)
Default: -
Password: yes
(∗) addressing: no
Opposite to: -
See also: RX, SE, Tab. 3.6

Example:
„ 2 NP 8 <CR>: allows to set the resolver pole number of axis 2 to 8
„ 2 MV 3000 <CR>: allows to set max velocity of axis 2 to 3000 rpm
„ 2 RN 12 <CR>: allows to set min R/D resolution to 12 bit (max R/D resolution with 8 poles/ 3000 rpm
according to Tab. 3.6)
„ 2 RN <CR>: questions axis 2 about the minimum of R/D resolution. The answer is: "A02 MINIMAL R/D
RES. = 12".

Tab. 3.6 - Max speed versus R/D resolution

Resolution (bit)
10 12 14 16
Max speed with 2 pole 24000 12000 3510 877
resolver (rpm)

Max speed with 6 pole 8000 4600 1170 292

resolver (rpm)

Max speed with 8 pole 6000 3510 877 219

resolver (rpm)

83 - 6/July/98
3.2.37 Command: RS - Resolver Shaft

Function: it informs about the phase shift between motor and resolver.
Syntax: data monitoring: „ address RS <CR>
data input: „ address RS n <CR>
Address type: axis
Unit of measure: -
Range: 0 to 65535
Default: -
Password: yes
(∗) addressing: no
Opposite to: -
See also: -

Examples:
„ 1 RS <CR>: the answer for axis 1 will be: "A1 RESOLVER SHAFT BIT = XXXXX". Where, if the
autophasing has been correctly made:
XXXXX = 14000 to 16000 for 6 pole motor and resolver or 8 pole motor and resolver
XXXXX = approx. 17000 or approx. 39000 or approx. 61000 for 2 pole resolver and 6 or
8 pole motor.

3.2.38 Command: RX - Maximum of R/D resolution

Function: it allows to set the maximum of Resolver to Digital converter

resolution. The R/D resolution will automatically be switched
according to actual speed for optimum system performance
between RN (minimum) and RX (maximum).
The default is 16 bit.
If acceleration [rad/s ] > 314000/NP, then RX must be set to 14.
2

If RX equals RN, the R/D resolution is fixed.

Syntax: data monitoring: „ address RX <CR>
data input: „ address RX n <CR>
Address type: axis
Unit of measure: bit
Range: 10, 12, 14 and 16 (it must be ≥ RN)
Default: 16
Password: yes
(∗) addressing: no
Opposite to: -
See also: RN, Tab. 3.6

Example:
„ 2 RX <CR>: questions axis 2 about the maximum resolution of R/D. The answer is: "A02 MAXIMAL R/D
RES. = 16" (if 16 bit R/D resolution has been set for axis 2).

84 - 6/July/98
3.2.39 Command: SA - Set Address

Function: it is used to assign the module a basic address different from

default. A module programmed as "address 1" will automatically
assign, for the other axes, the following address, i.e. 2 - 3 (if triple-
axis) or 2 (if double-axis).
Syntax: data input: „ address SA n <CR>
Address type: axis
Unit of measure: -
Range: 1 to 99
Default: 1
Password: no
(∗) addressing: no
Opposite to: -
See also: AS

REMARK: To perform SA command, only one module at the time must be connected to J2 flat cable.

3.2.40 Command: SE - SIMULATED ENCODER (OPTIONAL)

Function: it allows to set the number of pulses per electrical revolution of

simulated encoder.
The number of ppr must be ≤ ppr according to RN (see Tab.3.7)
Syntax: data monitoring: „ address SE <CR>
data input: „ address SE n <CR>
Address type: axis
Unit of measure: pulses per electrical revolution
Range: 128, 256, 512, 1024, 2048, 4096, 8192, 16384
Default: -
Password: yes
(∗) addressing: no
Opposite to: -
See also: RN, RX, Tab. 3.6 and 3.7

REMARK: to enable a new SE value (after setting and saving), reset button on front panel or
send pulse to REM reset.
Example:
„ 2 RN 12 <CR>: allows to set min R/D resolution for axis 2 to 12 bit.
„ 2 SE 1024 <CR>: allows to set the pulses per electr. revolution for axis 2 to 1024.

Tab. 3.7 - Max ppr versus R/D resolution

Resolution (bit)
10 12 14 16
Max number of pulses per 256 1024 4096 16384
electrical revolution

85 - 6/July/98
3.2.41 Command: SO - SPARE OUTPUT

Function: it allows to set the Analog Outputs on J8 connector.

Parameters 1SO (1st module), 4SO (2nd module) and 7SO (3rd
module) determine which signal is to be seen at the Analog
Out 1 (J8 conn., pos.4).
Parameters 2SO (1st module), 5SO (2nd module) and 8SO (3rd
module) determine which signal is to be seen at the Analog
Out 2 (J8 conn., pos.5).
The possible outputs are max current, velocity reference and
velocity error. The internal velocity reference has the
slope limited by AC and DE commands and differs from the
reference at the input connector
The analog outputs can be scaled via ES command.
Syntax: data monitoring(binary output): „ address SO <CR>
data input: „ address SO n <CR>
Address type: 1=Analog Output 1 for basic address 1 (see J8 connector, pos.4)
2=Analog Output 2 for basic address 1 (see J8 connector, pos.5)
4=Analog Output 1 for basic address 4 (see J8 connector, pos.4)
5=Analog Output 2 for basic address 4 (see J8 connector, pos.5)
7=Analog Output 1 for basic address 7 (see J8 connector, pos.4)
8=Analog Output 2 for basic address 7 (see J8 connector, pos.5)
Unit of measure: -
Range: 0 to 9. Analog Outputs:
SO1=max current axis 1 of the module
SO2=max current axis 2 of the module
SO3=max current axis 3 of the module
SO4=velocity reference axis 1 of the module
SO5=velocity reference axis 2 of the module
SO6=velocity reference axis 3 of the module
SO7=velocity error axis 1 of the module
SO8=velocity error axis 2 of the module
SO9=velocity error axis 3 of the module
Default: 1SO=1
2SO=2
Password: yes
(∗) addressing: no
Opposite to: -
See also: ES

Note: the SO command must be executed with digital Drive Enable disabled (via OF command) and the opto
Drive Enable enabled.

Example (see also the examples in ES command):

„ 4 SO 6 <CR>: sets velocity reference of axis 6 on Analog Out 1 (J8 connector, pos.4).

86 - 6/July/98
3.2.42 Command: SR - Show Release

Function: it is used to display the software releases of the system.

Syntax: data monitoring: „ address SR <CR>
Address type: module
Unit of measure: -
Range: 0.00 to 9.99
Default: -
Password: no
(∗) addressing: no
Opposite to: -
See also: -

Examples:
„ 1 SR <CR>: the answer can be: "SOFTWARE REL. MC 0.3 DSP 0.12" .

3.2.43 Command: ST - Status

Function: it allows to display axis status via a codified ASCII string.

Syntax: status monitoring: „ address ST <CR>
Address type: axis
Password: no
(∗) addressing: no

Answer explanation: A a ST b c d E e f g l h i j k l

A = Axis
a = Axis address

ST = Status
b = Priority (G2 jumper on person.card) 0 = opto (G2=1-2) 1 = keyboard (G2=2-3)
c = DRIVE OK opto output 0 = absent 1 = present
d = Expansion module 0 = absent 1 = present

E = External (opto input configuration)

e = DRIVE EN (Drive enable) 0 = OFF 1 = ON
f = REF EN (Reference Enable) 0 = OFF 1 = ON
g = N.C.

I = Internal (internal variables config.)

h = Drive Enable 0 = OFF 1 = ON
i = Reference Enable 0 = analog 1 = digital
j = I LIMIT (Current Limit) 0 = analog 1 = digital
k = System control 0 = velocity 1 = torque
l = Direction of rotation 0 = CW 1 = CCW
(viewed from shaft end)

87 - 6/July/98
3.2.44 Command: SV - Save

Function: it allows to save all parameters in the personality card. If the WP

jumper on the Personality Card is closed, the SV command is
disabled (see Par.2.2.7).
Syntax: command input: „ address SV <CR>
Address type: module
Unit of measure: -
Range: -
Default: -
Password: yes
(∗) addressing: yes
Opposite to: -
See also: -

CAUTION: the SV command execution time is 5s. If a reset has been sent during this time "EEPROM
ERROR" will appear and some data can be lost. In this case, the following steps must be met:
- close G3 on the personality card
- send 1SV command
- if the basic address is not 1, send 1SA command
- if 2-axis module, disable 3rd axis via AD command
- open G3 on the personality card

3.2.45 Command: TC - Torque Control

Function: it allows to pass from speed control to torque control. A torque

control proportional to the input reference (analog or digital,
positive or negative) will be applied to the motor. As for analog
reference, max. torque will be given according to max. voltage at
the input reference . As for digital reference, max. torque will be
given when a value equal to the maximum one (MV command) is
set via VE command. Note that, in that case, VE ("velocity")
and MV ("max. velocity") mean "torque" and "max torque". It is an
actual torque control and not a speed control, with limited torque
(see IL command).
Syntax: command input: „ address TC <CR>
Address type: axis
Unit of measure: -
Range: -
Default: velocity control
Password: yes
(∗) addressing: yes
Opposite to: VC
See also: IL, MV, VE, VC

Note: the status can be interrogated via ST command (bit K)

88 - 6/July/98
3.2.46 Command: VC - Velocity Control

Function: it allows to pass from torque to velocity control.

Syntax: command input: „ address VC <CR>
Address type: axis
Unit of measure: -
Range: -
Default: velocity control
Password: yes
(∗) addressing: yes
Opposite to: TC
See also: TC

Note: the status can be interrogated via ST command (bit K)

3.2.47 Command: VE - Velocity

Function: it allows to set velocity, in case the digital reference is enabled

(see DR command). If the drive is configured also as torque
actuator, it allows to set torque (see TC command). The
numeric value can be preceded by "-".
Syntax: data monitoring: „ address VE <CR>
data input: „ address VE n <CR>
Address type: axis
Unit of measure: n = rpm
Range: -9999 to MV
Default: 0
Password: no
(∗) addressing: no
Opposite to: -
See also: VC, MV

Note: the maximum range for - MV is -9999. To have extended range (up to 32000) for negative speed, it is
necessary to set +MV and to change direction via DI command.

Examples:
„ 1 VE 500 <CR>: it sets axis 1 to 500 rpm.
„ 2 VE -500 <CR>: it sets axis 2 to -500 rpm.

89 - 6/July/98
3.2.48 Command: VO - Analog Velocity Offset Automatic Setting

Function: it allows to automatically adjust the analog velocity offset

Syntax: command input: „ address VO <CR>
Address type: axis
Unit of measure: -
Range: 0 to 255
Default: 0
Password: yes
(∗) addressing: no
Opposite to: -
See also: OV

REMARK'S: The VO command must be executed with digital Drive Enable off (stopped motor). Before
executing the command it is necessary to check that the external opto input Drive Enable is
enabled and keyboard Drive Enable is off (OF command).

Notes: If error > 255, "OUT-OF-RANGE" is displayed.

90 - 6/July/98
3.2.49 Command: VS - VELOCITY STRUCTURE

Function: it allows to set 4 different structures of the velocity control. All the
structures have a digital low pass filter processing the speed
reference or the speed error signal. The cutoff frequency of this
filter can be adjusted by DF parameter (see DF). The value DF=0
switches the filter OFF.
VS=0 selects the speed controller having the feedback KP and KI
gains four times higher than the standard gains and a digital low
pass filter processing the speed reference signal.
This structure should be used in applications where the analog
speed reference lines from the CNC are noisy, and high gains are
required.
VS=1 selects the speed controller having standard feedback KP
and KI gains and a digital low pass filter processing the speed
reference signal.
This structure should be used in applications where the analog
speed reference lines from the CNC are noisy, and normal gains
are required.
VS=2 selects the speed controller having the feedback KP and KI
gains four times higher than the standard gains and a digital low
pass filter processing the speed error signal.
This structure should be used in applications with high ratios
between load and motor inertia (inertia mismatch), and high gains
are required.
VS=3 selects the speed controller having standard feedback KP
and KI gains and a digital low pass filter processing the speed
error signal.
This structure should be used in applications with high ratios
between load and motor inertia (inertia mismatch), and normal
gains are required.
Syntax: data monitoring: „ address VS <CR>
data input: „ address VS n <CR>
Address type: axis
Unit of measure: -
Range: 0 to 3.
VS=0: gains multiplied by 4, reference filtering
VS=1: standard gains, reference filtering
VS=2: gains multiplied by 4,error filtering
VS=3: standard gains , error filtering
Default: 1
Password: yes
(∗) addressing: no
Opposite to: -
See also: DF

Note: the VS command must be executed with digital Drive Enable disabled (via OF command) and the opto
Drive Enable enabled.

REMARK: to change DBM 01 with DBM 03 with same gains it is necessary to:
1. If PR=1 (motor poles=resolver poles) set VS=1 or VS=3
2. If PR≠1 (ex. FAS T motor with 2 pole resolver) set VS=0 or VS=2

91 - 6/July/98
3.3 Protections

3.3.1 Power Supply

Recovery not ok.

Indicated by: LED's DRVF (drive fault) on all drives, LED DBR FAULT, optoisolated output
DRIVE OK, bit H of the FA string (see FA command).

Set condition: when recovery power transistor or recovery resistor is broken, in short circuit;
when the recovery is active for too much time.

Effect: all drives inhibit torque

Reset condition: if the condition is not present anymore, power off and on monophase
voltage.

Power supply overtemperature.

Indicated by: LED's DRVF (drive fault) on all drives, LED OVER TEMP, optoisolated output
DRIVE OK, bit I of the FA string (see FA command).

Set condition: when a limit temperature is reached.

Effect: all drives inhibit torque.

Reset condition: if the condition is not present anymore, power off and on monophase
voltage.

92 - 6/July/98
3.3.2 Drive Module

Resolver not ok.

Indicated by: LED DRVF, LED RF (Resolver Fault), optoisolated output DRIVE OK, bit B of
the FA string (see FA command).

Set condition: when the resolver is not connected or in short circuit at the power up, when the
resolver fails or is disconnected during running.

Effect: the drive inhibit torque of all axes of the module.

Reset condition: if the condition is not present anymore, reset button on drive or send pulse
to REM RESET.

Motor over temperature.

Indicated by: LED DRVF, LED OVT, optoisolated outputs DRIVE OK and MOTOR OK, bit C
of the FA string (see FA command).

Set condition: when a limit temperature is reached inside the motor.

Effect: the drive inhibit torque of all axes of the module.

Reset condition: if the condition is not present anymore, reset button on drive or send pulse
to REM RESET.

Notes: the fault information via LEDS and opto is reset when the motor temperature goes
down the limit, while the drive is disabled until the reset condition has been met.

Short on axis.

Indicated by: LED DRVF, LED SHRT CCT, optoisolated output DRIVE OK, bit D of the FA
string (see FA command).

Set condition: when a short circuit is detected between the motor phases, phase and ground,
phase and HV.

Effect: the drive inhibit torque of all axes of the module.

Reset condition: if the condition is not present anymore, power off and on the aux power
supply.

93 - 6/July/98
Motor sequence not coherent.

Indicated by: LED DRVF, optoisolated output DRIVE OK, bit E of the FA string (see FA
command).

Set condition: when at level of current measurement, the three motor phases are not a triplet
or when a phase is greater than a fixed limit.

Effect: inhibit torque of all axes of the module.

Reset condition: if the condition is not present anymore, reset button on drive or send pulse
to REM RESET.

Auxiliary voltages not norm.

Indicated by: LED DRVF, optoisolated output DRIVE OK, bit N of the FA string (see FA
command).

Set condition: when the level of +/- 15V or 5V becomes out of tolerance.

Effect: inhibit torque of all axes of the module.

Reset condition: if the condition is not present anymore, reset button on drive or send pulse
to REM RESET.

Personality card absent

Indicated by: LED DRVF, optoisolated output DRIVE OK, bit L of the FA string .

Set condition: when the personality card is not present or taken away during running.

Effect: inhibit torque of all axes of the module.

Reset condition: if the condition is not present anymore, reset button on drive or send pulse
to REM RESET.

EEPROM error

Indicated by: LED DRVF, optoisolated output DRIVE OK, bit L of the FA string (see FA
command), "EE ERROR" on the keyboard.

Set condition: when, after the SV command, a reset has been sent before 5 sec.

Effect: inhibit torque of all axes of the module.

Reset condition: check the parameters (e.g. KP, KI,..), correct the wrong values and save.

94 - 6/July/98
Bus not normal.

Indicated by: LED DRVF, LED POWER OK, optoisolated output DRIVE OK, bit M of the FA
string (see FA command).

Set condition: See figure 3.2.

Effect: inhibit torque of all axes of the module .

Reset condition: if the condition is not present anymore at analog level (with hysteresis),
reset button on drive or send pulse to REM RESET.

FIG. 3.2. BUS BAR Voltage

3 9 5 V (o v e rv o lta g e )

3 7 5 V (R e c o v ery c irc u it e n a b le d )
3 6 5 V (R e s e t m a x v o lta g e )

300 V (B u s nom inal voltag e)

2 5 5 V (R e s e t m in v o lta g e )

1 9 0 V (U n d e rv o lta g e )

95 - 6/July/98
Auxiliary HV referred voltages not norm.

Indicated by: LED DRVF, optoisolated output DRIVE OK, bit N of the FA string (see FA
command).

Set condition: when the level of auxiliary voltages referred to power stage (-HV) becomes out
of tolerance.

Effect: inhibit torque of all axes of the module.

Reset condition: if the condition is not present anymore at analog level (with hysteresis) reset
button on drive or send pulse to REM RESET.

Drive overtemperature.

Indicated by: LED's DRVF and DRV OVT, optoisolated output DRIVE OK, bit O of the FA
string (see FA command).

Set condition: when a limit temperature is reached on the heatsink.

Effect: inhibit torque of all axes of the module.

Reset condition: if the condition is not present anymore power off and on monophase
voltage.

Notes: the temperature limit is detected by thermo-switch.

IT

Indicated by: LED DRVF, bit G of the FA string (see FA command).

Set condition: when the integral value IT ( integral of current in the motor multiplied by the
time ) is over taken.

Effect: when the fault is going on the current limit is reduced to the level of the motor rated
current (set by PC command).

Reset condition: if the condition is not present anymore, the protection is reset. Push button
on drive or send pulse to REM RESET to reset the fault status in FA string.

96 - 6/July/98
Watchdog.

Indicated by: LED DRVF, LED WTD, optoisolated output DRIVE OK.

Set condition: when the micro controller or DSP fails.

Effect: inhibit torque or all axes of the module.

Reset condition: if the condition is not present anymore reset button on drive or send pulse to
REM RESET.

Overspeed

Indicated by: LED DRVF, optoisolated output DRIVE OK, bit F of the FA string (see FA
command).

Set condition: when an error between set speed and actual speed bigger than the
programmed via EV command is detected.

Effect: inhibit torque on axis.

Reset condition: when the condition is no longer present, reset button on drive or send pulse
to REM RESET.

97 - 6/July/98
SECTION 4-TROUBLESHOOTING
FIG. 4.1 - DBM-PS Power Supply - AUX PWR green LED off
Auxiliary Power Fault

Green LED AUX POWER = OFF

NO
Connect single phase Auxiliary power supply
230 Vac (or 110 Vac, present?
optional) +/-10%

YES

Oversize the auxiliary NO Current supplied

power supply sufficient? (180 mA DC
(transformer, cable for 3-axis module)
size,..)

YES

NO
Replace the 3.15 A Internal 3.15 A fuse
fuse OK?

YES

Fault of auxiliary power

circuit

98 - 6/July/98
FIG. 4.2 - DBM-PS Power Supply - OVER TEMP red LED on
Overtemperature

Red LED OVERTEMP = ON

YES
Verify the correct Ambient temperature
cooling of cabinet > 45 °C ?

NO

NO
Power the fans with
230 Vac Fans powered?
(or 110 Vac)

YES

Output current >

nominal current
(100 A)

99 - 6/July/98
FIG. 4.3 - DBM-PS Power Supply - DBR FAULT red LED on
Recovery Fault

Red LED DBR FAULT = ON

NO Recovery
Connect the
recovery resistance resistance
connected?

YES

YES Recovery
Replace the recovery resistance open or
resistance short-circuited?

NO

YES
3-phase input 3-phase input voltage
overvoltage > 265 V?

NO

NO
Correctly tighten at
3 Nm (26 Lb in) the Bus Bars tightening
Bus Bars OK?

YES

Too much recovery

energy. Undersize the
duty cycle or oversize
the recovery resistance

100 - 6/July/98
FIG. 4.4 - DBM-PS Power Supply - PWR BUS yellow LED off

Yellow LED PWR BUS = OFF

NO Is 3-phase 230 Vac

Connect 3-phase +/-10% connected to
230 Vac DBM-PS?

YES

NO
Fault of 3-phase input Is 300 Vdc present
rectifier circuit on the Bus Bars?

YES

Fault of detecting fault

circuit

101 - 6/July/98
FIG. 4.5 - DBM Module - POWER OK green LED off

Green LED POWER OK = OFF

NO Green LED
See Fig. 4.1 AUX PWR on
DBM-PS lit ?

YES

Correctly tighten at NO Bus Bars

3 Nm (26 Lb in) the tightening
Bus Bars OK?

YES

NO
Flat cable between
Change flat cable
DBM-PS and DBM
module OK?

YES

Fault on module power

circuit

102 - 6/July/98
FIG. 4.6 - DBM Module - DRIVE EN green LED off
Drive Enable

Green LED DRIVE EN = OFF

Verify that 8.5 to 25Vdc NO

voltage with 8 mA min Internal +15V used?
current is applied to J8 (J8/pin 7)
and 0V to J8/pin 8.

YES

NO
J8/pin 6 (common)
Make connection
connected to J8/pin 8
(opto common)?

YES

Fault on input circuit

103 - 6/July/98
FIG. 4.7 - DBM Module - REF EN green LED off
Reference Enable

Green LED REF EN = OFF

Verify that 8.5 to 25Vdc NO

voltage with 8 mA min Internal +15V used?
current is applied to (J8/pin 7)
J8/pin 16 and 0V to
J8/pin 8.

YES

NO
J8/pin 6 (common)
Make connection
connected to J8/pin 8
(opto common)?

YES

Fault on input circuit

104 - 6/July/98
FIG. 4.8 - DBM Module - DRV OVT red LED on
DBM Overtemperature

Red LED DRV OVT = ON

NO
Power the fan with
230 Vac (or 110 Vac, Fan powered?
see nameplate)

YES

YES
Verify the correct Ambient temperature
cooling of cabinet > 45°C ?

NO

Undersize the duty

cycle(s)

105 - 6/July/98
FIG. 4.9 - DBM Module - SHRT CCT red LED on
Short Circuit

Red LED SHRT CCT = ON

YES Motor phases

Change motor short circuited or
grounded?

NO

NO Auxiliary
Change DBM-PS
voltages on
power supply
J1 connector
OK?

YES

NO
Change flat cable Flat cable on J1 OK?

YES

Fault on power stage

106 - 6/July/98
FIG. 4.10 - DBM Module - OVT red LED on
Motor Overtemperature

Red LED OVT = ON

NO Motor PTC
connected to J4,
Connect PTC
J5, J6?

YES

NO
PTC value at 20°C
Fault on motor PTC correct?
(100 to 400 ohm)

YES

Undersize the duty

cycle

107 - 6/July/98
FIG. 4.11 - DBM Module - RF red LED on
Resolver Fault

Red LED RF = ON

NO Is the resolver YES

shield connection Random fault ?
OK?

YES
NO

NO
Other resolver
Make correct
connection OK?
connection

YES

NO
Vref carrier present on J4, J5,
Fault on oscillator J6 (20 Vpp, 10 kHz)?
circuit

YES

NO
Resolver fault or Sin and cos signals
connection not OK at present on J4, J5, J6
(6.5 Vpp max, 10 kHz
motor side for Vickers resolver)?

YES

Internal fault

108 - 6/July/98
FIG. 4.12 - DBM Module - WTD red LED on
Watch Dog

Red LED WTD = ON

Reset via:
- Pushbutton on front
panel
- Remote Reset

YES
Fault caused by noise Red LED WTD =
OFF ?

NO

8031 or DSP fault

109 - 6/July/98
FIG. 4.13 - DBM Module - DRVF red LED on
Drive Fault

Red LED DRVF = ON

NO
Other red LEDs lit ?
Check via FA
command the fault not
reported by LEDs.
It can be:
- Not coherent phase
sequence
- Velocity error (see EV
command)
- Personality card not YES
present.
-Bus Bars overvoltage/
undervoltage.

See the figure with

the proper LED/fault

110 - 6/July/98
FIG. 4.14 - Motor vibrates

Axis enabled. Motor with

overspeed or running at a
speed not related to the
reference or vibrates

NO 6 resolver/motor
poles or
8 resolver/motor
poles ?

2 pole resolver
with 6 pole YES
motor?

YES

Check via RS
command. RS = NO NO
Check via RS command.
approx. 17,000 or RS = 14,000 to 16,000 ?
39,000 or 61,000?

YES
YES

Check power and

resolver connections. Internal fault.
Remake Autophasing.

111 - 6/July/98
FIG. 4.15 - Keypad fault

Keypad does not

work

NO
Serial cable and/or
J10 cable OK?

Make correct
connection
YES

YES
Baud rate > 9600 ?

Close G3 on
Personality Card
(Baud rate set to
9600)
NO

NO
Keyboard Baud
rate correct?

Adjust the keyboard YES

Baud rate:
<CTRL>
<CR>
<Y> to change Baud rate
<CR>

Internal fault.

112 - 6/July/98
FIG. 4.16 - Motor at zero speed

Axis enabled. Motor at zero

speed with speed reference
not zero

NO
REF EN = ON ?

Make REF EN = ON
on J8/pin 16
YES

YES AR = ON with
digital reference or
DR = ON with
analog reference?
NO

Check via ST
command. Use
coherent reference.
NO

YES
KI = 0 ?

Set correct value for KI NO

(standard value = 20)

Internal fault.

113 - 6/July/98
SECTION 5 - PRINCIPLES OF OPERATION

5.1 Introduction

In this chapter, principles of operation of the drive system comprising the DBM multi-axis
module and FAS T and FAS K synchronous motors with permanent magnet excitation will be
described. Theoretical background along with the necessary information specific for the DBM
will be outline, for the purpose of better understanding of the system, for the aim of a
comparison with other systems, and for the ease of the parameter adjustments during the
installation phase. Issues of particular importance are the torque generation, current control
loops and the speed control loop.

5.2 Torque Generation

The DBM is designed for the torque and speed control of synchronous motors with
permanent magnets on the rotor and with the sinusoidal distribution of the stator windings
along the stator circumference. Rather than "trapezoidal EMF" motors with concentrated
stator windings, these motors have sinusoidal electromotive force, induced in the windings
during the rotation of the rotor. Such motors have to be supplied with sinusoidal stator phase
currents. Having these currents shifted by 2π/3 relative to each other, and setting the stator
current frequency at ωr, the resultant magnetomotive force will be a vector Is rotating at the
rotor speed. The magnetomotive force angle relative to the rotor flux Ψr is marked θi (see
Fig. 1).

θ
i Ψr
Is ωr

θ
r

Fig. 1

114 - 6/July/98
Having a constant amplitude of phase currents, the current vector will rotate at ωr, having a
constant amplitude along the period. Hence, conditions of obtaining ripple-free
electromagnetic torque are fulfilled. The torque generation and the current control loops are
conditioned by the shaft sensor, which is giving the rotor speed and the rotor position
information. An application of synchronous motor calls for an absolute position sensor, in
order to set the current angle θi between the magnetomotive force and the rotor flux.

DBM is designed to interface with resolvers as the motor shaft sensors. Details of the
speed/position sensing are described in par. 5.4 . In Fig. 1, θr stands for the angular
displacement of the rotor flux with respect to the phase A winding of the stator. Assuming the
speed of rotation ωr,

θ r = θ0 + ω t. (1)

Electromotive forces, induced in the stator windings will be:

e A = Ψr ω r cos( θ r + π / 2)
e B = Ψr ω r cos( θ r − π / 6)
eC = Ψr ω r cos( θ r − 5π / 6)
(2)
In order to obtain the magnetomotive force vector as described in the Fig. 1, the stator phase
currents has to be:
i A = I s cos( θ r + θ i )
i B = I s cos( θ r + θ i − 2 π / 3)
iC = I s cos( θ r + θ i − 4 π / 3)

(3)

115 - 6/July/98
From the above equation, one can derive the power of the electromechanical conversion;
that is, the power flowing through the machine air gap as the consequence of mutual
interaction of the stator and rotor fluxes:
Pem = e A i A + e B i B + eC iC =
3
= ω r Ψr I s cos( π / 2 − θi )
2
(4)
The electromagnetic torque obtained by dividing the air-gap power with the field
frequency:

3
Tem = Ψr I s cos( π / 2 − θi )
2
(5)
From (4) and (5), one can conclude that the usage of the motor with the sinusoidal
electromotive force in the regime of sinusoidal current supply gives a shaft torque that does
not possess the torque ripple, inherent to the brushless DC motors with trapezoidal
electromotive force. As can be seen from (5), the torque depends on the amplitude of the
stator current and on the angular displacement between the rotor flux and the stator
magnetomotive force.

The DBM performs control of the torque magnitude through the stator current amplitude Is.
The phase advance θi of the stator current is set to +π/2 in the cases when it is necessary to
accelerate in the sense of ωr. For decelerating (with respect to the sense of rotation shown in
Fig. 1), the phase advance θi of the stator current is set to -π/2. Such a choice leads to the
maximum torque for the given stator current; that is, in the maximum Nm/A. In order to insure
maximized torque per amps, the DBM control software is equipped with "Auto phasing"
routine for the drive self-adjustment (see par. 3.2.5).

116 - 6/July/98
5.3 Current Control Loops

Control of the magnetomotive force of the stator is implemented through the PI control of the
stator phase currents. That is, the amplitude and the spatial orientation of the vector Is is
performed by controlling its components. Equation (3) gives the references of the motor
phase currents; that is, they are bringing out waveforms that should be the stator phase
currents. It can be seen that the amplitude Is plays the role of the torque demand, or the
torque reference. Apart of the torque reference, the derivation of the current references calls
for the information about the rotor position θr, which is obtained from a Resolver to Digital
converter, connected to the resolver mounted on the motor shaft.

Feedback - Uref Gating signals

Σ Kp + Ki/s sgn
+ Phase U

Reference PWM carrier

- Uref Gating signals
sgn
Σ
Phase W
-
PWM carrier
Feedback - Gating signals
Σ Kp + Ki/s sgn
+ Uref Phase V
Reference PWM carrier

Fig. 2

The phase currents U and V are measured by the LEM current sensors. These sensors
behave as current transformers capable of sensing both AC and DC components of the
current. The error discriminators (see Fig. 2) are determining the error, that is, the deviation
of the measured phase currents with respect to the references. The current references U and
V are obtained from the DSP, through the D/A channel, from the torque reference and using
the coordinate transformation from the rotor (d,q) to the stator (a,b,c) reference frame. The
current errors obtained are processed through the two PI current regulators.

The presence of 2, and not 3 current regulators for the 3 motor phase currents is due to the
fact that the phase currents are tied by the relation iA+iB+iC=0. Hence, only two of them are
mutually independent variables. Therefore, current control scheme possesses 2 PI
controllers; the introduction of the third (redundant) one will deteriorate the performances.

117 - 6/July/98
At the output of the PI current controllers for phases U and V, the reference values for the
phase voltages U and V is obtained. The reference voltage for the phase W is obtained by
Uw= -Uu+ Uv. The three voltage references obtained in the prescribed manner are brought to
the PWM modulation block.

The comparators in Fig. 2 (labeled "sgn") are supplied by the triangular PWM carrier .
Comparison of the modulation signals (that is, the voltage references) with the PWM carrier
gives gating signals. These signals consist of pulses with the width determined by respective
modulation signal. The nature of this signals is digital (either 0 or 1). Their state determines
the three phase inverter switching. Finally, the average phase voltage, brought to the motor
winding, corresponds to the voltage references shown in Fig. 2.

Since the implementation of the scheme in Fig. 2 is analog, proportional and integral gains of
the current controller are determined by the value of resistors and capacitors used. For the
purpose of allowing the matching of DBM with a non standard motor, these components are
mounted on a removable plug-in modules, namely, the PWM90 hybrids. These hybrids are
fitted into the drive during the factory test. At this time, the current gain is adjusted according
to the motor that is going to be used in conjunction with the drive. Current gains are
optimized in the sense of maximizing the current loop bandwidth, while still keeping the noise,
current ripple, and overshoot at an acceptable level.

The bandwidth of the current loop lies in the range of 900-1200 Hz. In terms of the torque
response time, the motor fed from a DBM will respond to the torque command with a rise
time 200 µs.

118 - 6/July/98
5.4 Speed and Position Sensing

The DBM multi-axis drive is equipped with an interface for resolver-type shaft sensors. These
sensors are preferred for the reason of inherent absolute position sensing, much wider
operating temperature range than the optical devices, and a robustness intrinsic to the
resolver mechanical mounting (that is, the one of an electric machine). Resolvers have a pair
of detection windings on the stator side, name "SINE" and "COSINE" winding, spatially
displaced by 90 degrees. Excitation of the resolver is performed by a 10kHz, 7Vrms
sinusoidal signal, supplied to the resolver from the DBM module. By means of a rotational
transformer, fitted within the resolver, the excitation is being fed to the excitation winding
installed inside the rotor of the resolver. Through a transformer action, 10kHz electromotive
forces will be induced in the detection winding.

The amplitude (and phase) of these electromotive forces depend upon the shaft position.
Namely, when the shaft is in such a position that the rotor excitation winding of the resolver is
aligned with the "SINE" detection winding, the induced electromotive force in the "SINE"
winding will be on its maximum, and will be in phase with the excitation signal. At the same
time, the voltage detected at the terminals of the "COSINE" winding will be close to zero (i.e.,
will be zero if we disregard the noise). Moreover, assuming that the "SINE" winding spatial
axes is in opposite direction with respect to the excitation winding, the situation will be alike,
but the "SINE" winding voltage will be in counter-phase with respect to the excitation signal.
In the end, the ratio of the "SINE" and the "COSINE" signals taken at the instant of positive
peak of the excitation sinusoid will uniquely determine the shaft position.

119 - 6/July/98
The process of extracting the shaft position from the detected signals is done by means of a
monolithic R/D converter (see Fig. 3). The key element is the ratiometric resistive net. The
digital counter in Fig. 3 contains the shaft position information in the form of a digital word.
Specific bits of this digital word are fed to the resistive net, in order to commutate internal
resistances within the net. Analog net inputs are supplied by detected SINe and COSine
signals, fed from the resolver to the DBM module by a shielded cable. The net is made in
such a way that its output (that is, the AC error in Fig. 3) is zero if the digital word correspond
to the current shaft position, i.e. to the ratio of the SINe and COSine signals.

If the digital word does not correspond to the measured SIN/COS ratio, the AC error signal
will be generated. The amplitude of the AC error will correspond to the magnitude of the
existing difference between the SIN/COS ratio and the digital position stored in the
UP/DOWN counter. The phase of the AC errors signal is determined by the error sign. For
positive errors, the AC error will be a 10kHz sinusoid in phase with the excitation signal, and
vice versa. Due to the presence of the high frequency noise, the AC error signal has to be
filtered by an high frequency RC filter (HF FILTER block in the Fig. 3). The process of
demodulation of the error is, in effect, a form of multiplication of the AC error by the excitation
signal. As the result of this operation, an error signal is obtained, having the average value
correspondent to the R/D converter internal error. Hence, the function of the "phase sensitive
demodulator" in Fig. 3 is to express the internal angular error in the form of a DC signal.
This signal is, in turn, fed to the input of a PI error analog amplifier.. The presence of the
integral action insures that the steady state error will be zero.

The output of the PI error amplifier is fed to the UP/DOWN Voltage Controlled Oscillator. The
function of this block (see Fig. 3) is similar to the conventional VCO. The difference is that the
VCO used is able of accepting bipolar input signals. In other words, the positive input signal
fed to the VCO will produce UP counts of the digital counter, with a frequency proportional to
the magnitude of the input signal. In situations where the input to the VCO is negative,
resulting counts will be DOWN, i.e. decrementing. This way, the R/D converters position
tracking loop is closed. The digital word from the UP/DOWN counter is read by the DSP.
Position information is used for the purpose of performing the rotational transformation of
variables from the rotor d-q coordinate frame to the stator stationary a-b-c frame. Moreover,
the shaft position, taken in the form of a digital word, serves as the input to the speed
observation block, illustrated in Fig. 4:

120 - 6/July/98
5.5 Speed Loop

The speed control loop is implemented by the Digital Signal Processor fitted into the DBM
module control board. The speed reference normally comes from a CNC in the form of
+10V/-10V analog signal. Alternatively, the speed reference might be set by a dumb terminal
or a PC computer, through the RS485 serial link. Speed control loops of the axes are
completely independent of each other. The feedback for the speed loop error discrimination
is obtained from the velocity observer, illustrated in Fig. 4. Simplified block diagram of the
speed control loop is given in Fig. 5, presented in a form suitable for easier understanding of
feedback gains. This block diagram should be used for the estimation of the drive
performance in the stage of system selection and sizing.

Gain correlator and AWU

Speed + ω[rad/s]
Ko Σ p + i/s KD
K1 1/(Js)
reference
-
[rad/s] T [Nm]
observer
Ko Fig. 5

The speed observation constant Ko in Fig. 5 is Ko=50.06 [1/(rad/s)]. The K1 block in Fig. 5
approximates the drive power section and the motor. It is assumed that the response of the
current control loop may be neglected with respect to the dynamics of the speed loop.

Notice: As the result of more detailed analysis, that takes into account the interaction of both
loops, it is concluded that said simplification results in an error of less than 2%. Hence, the
user is encouraged to use Fig. 5 simplification as a toll for the system performance
estimation.

The value of the parameter K1 may be calculated from the drive peak current (25 A in the
case of DBM 10/25) and the motor torque constant Kt:

I peak [ A]∗ Kt [ Nm / A]
K1[ Nm] =
1e6
(6)

121 - 6/July/98
The quantity J in Fig. 5 stands for the total motor+load inertia in [kgm2]. The values of the
feedback parameters p and i are influenced by the numerical values KP and KI, imposed by
the user via serial link. Moreover, particular control routines performing the correlation and
the AWU (Anti Wind Up) are influencing the values of the gains internal to the Digital Signal
Processor. These routines are designed so as to optimize the drive performance in various
operating conditions and to alleviate the problems of noise and imperfection of the current
controller. In the simplified analysis, illustrated in Fig.5, their influence on the gains should be
neglected.

Relation between the gains p and i in Fig. 5 and the parameters KP and KI imposed by the
user is given by:

p = 8. 31 ∗ KP
i = 1635 ∗ KI (7)

The range of parameters KP and KI is: 0 to 255. For typical 5-10 Nm motor connected to the
load having 3-5 times the motor inertia, the speed loop bandwidth can up to 60Hz, having at
the same time the torque ripple below 1.5%. Higher bandwidths might be obtained at the
penalty of an increased torque ripple. In a typical application, the torque ripple is originated
by the noise at the drive analog inputs, imperfection of the sensors and finite resolution of
A/D and D/A converters applied within the drive control board.

122 - 6/July/98
SECTION 6 - ELECTROMAGNETIC COMPATIBILITY (EMC)
6.1 European Directive (89/336/EEC)

Compliance with the European Directive 89/336/EEC is required for all electric and electronic
products brought onto the European market after December 31st, 1995.
DBM03 drives with FASTACT motors meet the following EMC product standard related to the
Directive:

EN 61800-3 (1996) and EN 61800-3/A11 (2000): "Adjustable speed electrical power drive
systems. Part 3: EMC product standard including specific test methods".
Second environment (industrial) compatibility levels.

Remark: equipments not intended to be used on a low-voltage public network which supplies
domestic premises. May cause radio frequency interference.

Tests have been made in an independent, competent body, test house.

The installer of the drive is responsible for ensuring compliance with the EMC regulations that
apply where the drive is to be used. We recommend filtering as per par.3.2 and wiring,
grounding and screening as per par.3.3 and 3.4.

6.2 Filtering

6.2.1 Filter Types

Code Trade-mark Rated Current Max Voltage Drive type

[A] [Vac]
at 50°C (40°C) at 50°C
AT6008 Schaffner (6) 250 DBM03 PS (Aux)
FN 250-6/07
AT6009 Schaffner 7 (8.4) 3 x 480
FN 258-7/07
AT6010 Schaffner 16 (19.2) 3 x 480
FN 258-16/07
AT6011 Schaffner 30 (36) 3 x 480
FN 258-30/07
AT6012 Schaffner 42 (50.4) 3 x 480
FN 258-42/07
AT6013 Schaffner 55 (66) 3 x 480
FN 258-55/07
AT6014 Schaffner 75 (85) 3 x 480
FN 258-75/34
AT6015 Schaffner 100 (120) 3 x 480 DBM03 PS
FN 258-100/35

123 - 6/July/98
 6.2.2 FILTER SIZING

The filter/drive coupling in the previous table is a standard coupling. The filter can be
undersized according to the rms input current of the actual application. This should be done
not only because, as a matter of fact, undersizing the filter means less money, but because
the undersized filter provides better performance to EMC.

Example:

- DBM PS 03 + DBM 03 5-5-5 + DBM 03 5-5-5 and contemporaneity factor of 0.8.

For this application it is not necessary to use the 100A filter of the table.

The reference current is Iin = 6 ∗ 5 ∗ 0.8 = 24 A

A 30A filter (FN 258-30/7) can safely be used.

6.2.3. FILTER DIMENSIONS

Code Trade-mark Dimensions Weight

[mm]
L1 L2 L3 L4 L5 L6 l7 [kg]
AT6008 Schaffner 85 75 54 0 65 30 300 0.24
FN 250-6/07*
AT6009 Schaffner 255 240 50 25 225±0.8 126±0.8 300 1.1
FN 258-7/07
AT6010 Schaffner 305 290 55 30 275±0.8 142±0.8 300 1.7
FN 258-16/07
AT6011 Schaffner 335 320 60 35 305 150 400 1.8
FN 258-30/07
AT6012 Schaffner 329 314 70 45 300 185 500 2.8
FN 258-42/07
AT6013 Schaffner 329 314 80 55 300 185 500 3.1
FN 258-55/07
AT6014 Schaffner 329 314 80 55 300 220
terminal 4
FN 258-75/34 block
AT6015 Schaffner 379±1.5 364 90±0.8 65 350±1.2 220±1.5 terminal 5.5
FN 258-100/35 block

*= the FN250-6/07 filter has wiring leads (length=300mm) at both sides.

TOP VIEW SIDE VIEW

L5 L7
L1

L2

L6

L3 L4

124 - 6/July/98
6.2.4 FILTER INSTALLATION

- The filter must be mounted on the same panel as the drive.

CAUTION: leave a clear space of at least 60mm around the filter for air circulation when the
cabinet does not have forced ventilation.

- The filter must be connected as close as possible to the drive input. If the separation
between filter and drive exceeds around 30 cm (1 ft.) then a flat cable should be used for
the RF connection between filter and drive

REMARK: when mounting the drive and the filter to the panel, it is essential that any paint or
other covering material be removed before mounting the drive and the filter.

- The maximum torque of mounting screws - The filter can produce high leakage
is as follows: currents (see Table)

FILTER Max FILTER Leakage current*

torque FN 250 - 6/07 1.3 mA
FN 250 - 6/07 0.8 Nm FN 258 - 7/07 17 mA
FN 258 - 7/07 0.8 Nm FN 258 - 16/07 19 mA
FN 258 - 16/07 0.8 Nm FN 258 - 30/07 25 mA
FN 258 - 30/07 1.8 Nm FN 258 - 42/07 26 mA
FN 258 - 42/07 1.8 Nm FN 258 - 55/07 26 mA
FN 258 - 55/07 3.0 Nm FN 258 - 75/34 26 mA
FN 258 - 75/34 3.0 Nm FN 258 - 100/35 26 mA
FN 258 - 100/35 4.0 Nm
* Note: if two phases are interrupted, worst case
leakage current could reach 6 times higher levels

- The capacitors within the filters have FIG. 6.1 - FN 250-6/07 FILTER
discharge resistors. INSTALLATION ON DBM 03 DRIVE

CAUTION: the filter must be connected

to ground before connecting the supply

WARNING: HIGH VOLTAGE -

DISCHARGE TIME APPROX. 10 To
seconds Fans

- Where single phase power supply is

needed, the single phase filter can be
installed on the fan housing.
Figure 6.1 shows installation and wiring
of FN 250 6/07 filter on fan housing of
DBM 03 drive.

230V G
N
D

125 - 6/July/98
6.3 WIRING AND GROUNDING FIG. 6.3 - GROUNDING OF SHIELD TO
CONNECTORS AT MOTOR SIDE
All the following cables must be shielded,
with 85% minimum shielding coverage:

- power motor cable (see Fig.6.2 and 6.3)

NOTES: if a power terminal board is used at motor

side, the shield must be RF connected to to a
metallic PG gland.
- connectors at motor side can have a threaded
clamp. Cable shield must be grounded in the same
way as in Fig.6.3.

- resolver cable (see Fig.2.3 and 6.3 motor

side)

FIG. 6.2 - GROUNDING OF SHIELD TO In case of Sub-D connector, cable shield

MOTOR CONNECTOR AT DRIVE SIDE must be grounded to the metallic hood.

When there is not connector at drive side,

a kit with stand-off, screws and hose
clamps is provided.

The shield of the cable must be uncovered

from insulation coating and RF connected
to the stand-off through the hose clamp, as
in Fig.6.4.

- recovery resistor cable FIG. 6.4 - GROUNDING OF SHIELD

CAUTION: the unshielded cable WITHOUT CONNECTOR
provided with the drive is only for test
purposes and not EMC compliant.

- Reference, Enable and OK cable

- RS485 cable (flat cable between modules
excluded)
- simulated encoder cable (if applicable)

The shields of the cables must be

connected at both ends to the proper
housing via full circumferential bond to
metallic connectors or hose clamps.

126 - 6/July/98
FIG. 6.5 - CABLE GROUNDING AT DRIVE SIDE

1 = Reference, Enable, OK cable

2 = Recovery resistor cable
3 = Motor power cable
Sub-D and unshielded cables not shown

127 - 6/July/98
It is not necessary to shield the input power wires, the bus bars, the flat cables between the
modules.

REMARKs: FIG. 6.7 - PARTITION PENETRATION

- the shields of cables inside the cabinet
must be 360° clamped to the cabinet wall Strap
Enclosure Cable Shield
(see Fig. 6.6).
- "noisy" cables must be kept away from
"sensitive" cables by at least 30 cm (12 in).
Noisy cables include input-power wires,
motor power and brake wiring. Sensitive
cables include analog or digital signal Hex Head
cables: resolver cable; reference, enable Bolt
and OK cable; RS485 serial link; simulated
encoder wiring.
- where noisy cables must cross power
cables, this must be done with angles as
near to 90° as possible.

FIG. 6.6 - CLAMPING TO CABINET

- the crossing of the cabinet should be
Backpanel
accomplished with a low impedance
(earth)
connection between cable shield and
enclosure. If a connector is not involved,
the shortest practical lengths of connecting
strap should be used (see Fig.6.7).

Screen is effectively
earthed 360° of its
radius

6.4 RECOVERY RESISTOR / MOTOR CHOKE

To meet the Machinery Directive "the ventilated enclosures containing dynamic braking
resistors shall provide a degree of protection of at least IP22" (EN 60204-1, par. 13.3).
To meet the EMC Directive, these enclosures must be conductive. The cable of recovery
resistor must be shielded and the shield must be 360° clamped at both sides.
In some applications (e.g. some size 3 FAS T motors) a choke in series for each motor phase
has to be added. This choke must be shielded.

REMARK: when mounting the enclosure of recovery resistor or motor choke to the panel, it is
essential that any paint or other covering material be removed before mounting the enclosure
of recovery resistor or motor choke.
128 - 6/July/98
6.5 SCREENING

To effectively screening the system all the single screens (CNC, electronic cabinet, machine,
motor housing, cables) must be connected together to effectively form one screen.

FIG. 6.8 EMC GENERAL WIRING/SCREENING

129 - 6/July/98
6.6 SAFETY ASPECTS

Noise suppression of Motor and Drive systems involves consideration of the earthing system,
and its effectiveness at high frequencies. It should not be forgotten that is the safety system
too and that the safety must take priority over EMC.
To reduce the radiated emissions, the use of capacitance to earth is very effective. In fact
DBM03 drives have Y-type capacitors near the input power supply connector and Schaffner
filters also include them. These capacitors conduct current from phase to earth; this can be in
the order of hundreds of milliamperes.

WARNING: appropriate safety measures should be taken to ensure that this

potentially dangerous current flows to earth.

CAUTION: it is recommended to disconnect the drive and the EMC filters to carry out
the "AC Voltage Test" of the EN 60204-1 (par.20.4), according to the Machinery
Directive (89/392/EEC) and to the Low Voltage Directive (73/23/EEC) in order not to
damage the Y-type capacitors between phases and ground while parts of circuits can
be floating and possibly damaged during the test.
To make anyway this test it is recommended contacting our Service Centers.

130 - 6/July/98
APPENDIX A - SERIAL LINK MULTIDROP

A.1 DBM-PS Internal Jumpers (see par. 1.6)

In case of multidrop, the following configuration must be used.

JP1,JP2,JP3 JP1,JP2,JP3 JP1,JP2,JP3 JP1,JP2,JP3

To user open open open closed

Power Power Power Power

Supply Supply Supply Supply

A.2 Personality Card Jumpers (see par.2.2.7.1)

By default G1, G4 and G5 jumpers on the personality card are open (no link termination's on
modules). In fact, usually, it is not necessary to close G1, G4 and G5 jumpers because the
link termination's are already closed on the power supply; anyway, in specially noisy
environments, could be necessary to close them also, as follows.

• Environment without noise

To user JP1,JP2,JP3 G1,G4,G5 G1,G4,G5 G1,G4,G5 G1,G4,G5

(see par.D.1) open open open open

Power
Supply Module Module Module Module

• Specially noisy environment

To user JP1,JP2,JP3 G1,G4,G5 G1,G4,G5 G1,G4,G5 G1,G4,G5

(see par.D.1) open open open closed

Power
Supply Module Module Module Module

131 - 6/July/98
APPENDIX B - DBTALK
To help you communicate with DBM/DBS • MANUAL to
drives quickly and easily, DBTALK provides ⇒ See/Reset Faults
several features: If the fault condition is not present anymore, the fault
• SETUP to choose will be reset automatically. To reset the fault on the
screen, go to the next screen with the arrow keys
⇒ Language: Italian or English
⇒ Serial link : COM1 or COM2

⇒ Display the Status

• UTILITY to
⇒ Scan Baud rates

⇒ Scan Faults
⇒ See/Change parameters
To change one parameter type the command string (see
Drive Manual) on the PC keyboard. Example: 3VE3000

⇒ Restore/store Personality Card parameters

To save the actual parameter set, select STORAGE
PARAMETER, select the file (e.g. ST1), press <TAB> to
change the description and press <CR>

⇒ Set Baud rates

⇒ Start the Autophasing procedure
⇒ Set Defluxing (see DBS User's Manual)

132 - 6/July/98
• INTERFACE REQUIREMENTS • PC REQUIREMENTS
The RS422 interface wiring is based on one-to- - 80286, 80386, 80486 microprocessor or better
one, no multidrop, principle. Four wires are - Hard disk and one diskette drive. You need 2
used. With RS422, you can transmit and Mbytes of disk space and 512 kbytes of RAM
receive data simultaneously (full-duplex). - CGA, EGA, VGA, MCGA graphics card (color
The RS485 half-duplex uses only two wires. It VGA recommended)
allows multidrop communication. With RS485 - MS-DOS 6.2 or later
half-duplex, you cannot transmit and receive - ANSI.SYS in CONFIG.SYS
simultaneously.
DBM03 supports RS485 full-duplex with four
• DBTALK PROGRAM
wires (RS422 compatible). Up to 99 DBM and
The DBTALK program is available on floppy
up to 15 DBS drives can be connected in
disk
multidrop configuration.

⇒ RS232/485 CONVERTER KIT • INSTALL PROGRAM

This very small external converter provides a - Insert diskette into drive A or drive B
full-duplex interface between PC and - Type <a:install> (or <b:install>)
DBM/DBS. The installation program will create the Directory
C:\DBTALK, will copy all the files in this new directory
The converter must be fit directly into a COM and will start the program
port (RS232) of a PC. This way the link
becomes purely RS485, less susceptible to
noise and able to transmit over much longer • START PROGRAM (after the first
distances than RS232. installation)
- Type <cd dbtalk>
The kit includes: - Type <start>
- the converter to fit into DB25-S connector of
the PC (COM port)
The DTE/DCE switch of the converter must be set to DCE • MOVE IN THE PROGRAM
(Data Communications Equipment)
- a DB25 to DB9 interface (to be used if the PC Start the selected procedure
COM port is DB9-S)
- a 2 m cable to connect the converter to DBM Select the field
J10 connector or DBS J2 connector Space Reread parameters
⇒ An opto-isolated PC card RS 485 full-duplex Move up/down
is also available. The following wiring must Go to previous/next screen
be used.
Esc Exit/Go to previous menu

RS485 full duplex DBM J10 Connector

Connector DBS J2 Connector • SELECT PROGRAM
Male Female ⇒ DBM linker
(+Tx) 1 (+Rx) ⇒ DBS linker
(-Tx) 2 ⇒ PDBS Linker (see PDBS Application Manual)
(+Rx) 3 (+Tx) ⇒ Setup
(-Rx) 4-5
(Gnd) 6 (-Rx)
7 (Gnd)
8 (-Tx)
9

133 - 6/July/98
APPENDIX C - MODULE REPLACEMENT

Once DBM module to be replaced has been identified, it is necessary to follow this procedure:

• Disconnect the power.

• Remove the Bus Bars (+AT, -AT and GND) and disconnect all connectors and flat cables
(see Fig. 1.1).
• Unscrew the anchor screw on the top of the module and remove the module.
• Only for same DBM versions:
Remove the Personality Card, at the left of J1 connector, by loosening the two screws. After
removing the card, disconnect the flat cable.

REMARK: on the personality card a EEPROM is mounted. All dynamic parameters (dynamic
settings, autophasing, analog interfaces, ...) are stored in this EEPROM after every reset.
In case of module replacement, it is recommended to save all parameters with the save (SV)
command before removing the Personality Card ready for installation in the replacement
module. This retains and transfers all the previous module information's.

Remove the Personality Card from the new module and replace with the old one.

• Mount the new module and tighten the anchor screw at the top.
• Reassemble the Bus Bars, all the connectors and flat cables.
• Check all connections.
• Enable the auxiliary voltage and check by the optional keyboard or PC all application dependent
parameters. In particular: pole number, max velocity, max reference voltage, Ilimit, internal ramp
generator.

CAUTION: personality card of DBM 03 has a software different from DBM 01 personality
card. Do not swap personality cards between the two versions.
To change DBM 01 with DBM 03 see Par.2.2.7.

134 - 6/July/98
APPENDIX D - INPUT SIZING

D.1 Sizing of Power Transformer/Autotransformer

It is necessary to refer to the rated output power of the motors (the output power with 65K
winding overtemperature is included in the Technical Data table of catalogs of servomotors), to
sum the power of single axes, to multiply the sum by the contemporaneity factor (factors often
utilized are Kc=0.63 for 2 axes, Kc=0.5 for 3 axes, Kc=0.38 for 4 axes, Kc=0.33 for 5 axes, Kc=0.28
for 6 axes), and by a correction coefficient (=1.2), accounting for the losses of the motor/drive
system.

P = Σ Pim ∗ Kc ∗ 1.2 [W]

D.2 Sizing of Fuses

It is necessary to divide the above calculated power by the 300 V DC Bus.

If = P / 300 [A; W, V]

Fuses must be the delay type because of high peak current inrush of the internal capacitors.

D.3 Auxiliary Power Transformer

Auxiliary power (55 W for each 3-axis module) and fan power (60 W for each pair of fans) must
be added.

D.4 Thermal sizing of cabinet

To calculate cabinet cooling requirements, table below provides estimated equipment power
dissipation values. If the application employs continuous braking, it is necessary to include
the recovery resistor power dissipation (use the nominal power of recovery resistor if actual
application recovery dissipation is unknown).

Power Dissipation
Power Module IGBT's Input
Supply Bridge
25 W 50 W 16 W/A 1 W/A

Example: with one Power Supply, two modules, a total output current of 60 Arms and continuous
uncalculated braking, the dissipated power is as follows.

Pd = 25 + (2 ∗ 50) + (16 ∗ 60[A]) + (1 ∗ 60[A]) + 370 [recovery resistor power] = 1515 W

135 - 6/July/98
APPENDIX E - MECHANICAL BRAKE

FAS series servomotors have as option a 24 Vdc electromagnetic safety brake.

CAUTION: safety brake must be clamped and released with motor at standstill.
Dynamic brakings can seriously damage the brake and reduce the braking torque.

The release of the brake (from 0V to +24V) and the clamp (from +24V to 0V) must follow the
sequence in Fig. E.1.

FIG. E.1 - Braking Sequence, Timing Chart

Note: T1 ≥ 200 ms, T2 = application dependent, T3 = 100 ms, T4 ≥ 200 ms

T1 T2 T3 T4

ON
OFF
D RIV E E N A BLE

ON
OFF
B RA KE 24V
P OW E R SU P PLY

RELEASE
CLAMP
BRAKE

0V R E FE R E N C E
E N AB LE

0 rpm
M OTOR SP EE D

136 - 6/July/98
 Moog Italiana S.r.l.
Electric Division
Via Avosso, 94
16015 Casella GE
Italy
Phone: (+39) 010 9671
Fax: (+39) 010 9671 280

GB-4019 Rev.9 - July/98 Moog Italiana Srl reserves the right to alter any dimensions or data without prior notice Printed in Italy