Customer handbook AC-Servocontroller DAC deltadrive

CUSTOMER HANDBOOK

Maintenance and service

Customer handbook 05-2002 Page 1

deltadrive Customer handbook AC-Servocontroller DAC

Contents

1. Security specifications ............................................................................................................. 4

2. General information .................................................................................................................. 5

2.1 The deltadrive Group ......................................................................................................... 5

2.2 Short description of the deltadrive ................................................................................... 5
2.3 Declaration of EU conformity ............................................................................................ 6

3. Device description .................................................................................................................... 8

3.1 Technical data..................................................................................................................... 8

3.1.1 Acceptable environment, ventilation, housing................................................................ 9
3.1.2 Conductor cross section ................................................................................................ 9
3.1.3 Fusing ............................................................................................................................ 9
3.1.4 LED displays ................................................................................................................ 10
3.2 Dimensions ....................................................................................................................... 11
3.3 Front view showing service features and connections ................................................ 12

4. Assembly and wiring................................................................................................................. 13

4.1 General guidelines ............................................................................................................... 13

4.2 Connector pin assignment .............................................................................................. 14
4.2.1 Motor connection (plug X1).......................................................................................... 14
4.2.2 Mains an DC bus connection (plug X2) ....................................................................... 14
4.2.3 Network connection RS485 (plug X3 and X4) ............................................................. 14
4.2.4 Signal connection (plug X5) ......................................................................................... 15
4.2.5 Encoder connection (plug X6)...................................................................................... 15
4.2.6 Signal connection (plug X7) ......................................................................................... 16
4.2.7 Options connection FB100 (plug X11) ......................................................................... 17
4.2.8 RS-232 interface PC connection (plug X10) ................................................................ 18
4.2.9 Options connection FBK100 (plug X11)....................................................................... 18
4.2.10 RS - 422 interface FBK100 (plug X10) ........................................................................ 19
4.2.11 Shielding connection....................................................................................................19
4.2.12 Ground connection.......................................................................................................19
4.2.13 Interface module (plug X7 / plug X11) ......................................................................... 20
4.3 Arrangement of jumpers.................................................................................................. 22
4.3.1 Rearranging the jumpers ............................................................................................. 23
4.5 Automatic station address detection................................................................................... 24

5. Software installation............................................................................................................... 25

5.1 Software installation with the FBK100 card................................................................... 25

6. Servicing.................................................................................................................................. 26

7. Trouble-shooting .................................................................................................................... 26

7.1 Servomotor problems ...................................................................................................... 26

7.1.1 Encoder-fails setup check............................................................................................ 26
7.1.2 Blocked motor .............................................................................................................. 26
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Customer handbook AC-Servocontroller DAC deltadrive
7.2 Problems with the deltadrive-controller......................................................................... 26
7.2.1 Communications check................................................................................................ 26
7.2.2 Controller doesn't start................................................................................................ 27
7.2.3 LEDs blinking on controller ......................................................................................... 27
7.2.4 Motor starts turning immediately................................................................................. 27
7.2.5 Motor vibrates ............................................................................................................. 27
7.2.6 Motor "whistles" .......................................................................................................... 27
7.2.7 Analog inputs and outputs not functioning.................................................................. 27

8. Connector assignments for customer's application ........................................................... 28

8.2. Additional inputs and Outputs (plug X11) ..................................................................... 29

9. Three phase synchronous motors........................................................................................ 30

9.1 Frame type references ..................................................................................................... 30

9.2 Options.............................................................................................................................. 30
9.3 Datasheet SAC 118M20.................................................................................................... 31
9.4 Datasheet SAC 90L20 ...................................................................................................... 32

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deltadrive Customer handbook AC-Servocontroller DAC

1. Security specifications

deltadrive is constructed in accordance with the latest security specifications and with a high
degree of protection against accidental contact.
Appropriate use of the deltadrive:
• deltadrive is to be used as a control device for synchronous and asynchronous machines.

The following security specifications and manipulation limitations are for the
personal safety of individuals and of equipment and are to be strictly observed.
• The user is therefore responsible for proper installation and connections of motor,
deltadrive and additional equipment in accordance with the recognized technical
regulations and guidelines applicable in the country and region of its destination and use.
• Thus it is important to be aware of (and employ) correct cable dimensions, shielding,
grounding, switch-offs, separation and over-current protection.
• All local specifications and regulations must be observed without fail.
• Any operation on the device can only be undertaken by experts trained for this purpose.
• Any operation on the device can only be performed using appropriate tools.
• Any operation on the deltadrive is to be undertaken only in a voltageless condition, i.e.,
neither the power source nor any potential auxiliary supply nor the rating voltage of another
connected device can be switched on. Take care to have a secure isolation braker. For
additional security employ the appropriate warning signs, physical barriers, etc.
• As a result of the device-internal electrical charge, high voltage can exist for a lengthy
period even after the main's voltage has been switched off. Before electrical contact is
made, take care to insure that the voltage between the power clamps A+ and D- is less
than 40V. Failure to follow this advice can lead to serious injury or even death.
• No additional cards, ICs, plugs, etc. can be inserted or removed under voltage.
• Changes may not be made to the deltadrive without the permission of the manufacturer.

If these security specifications and operation limits are not strictly observed, the
risk of danger exists via:
• Accident - from uncontrolled movement of parts, motors or machines.
• Destruction of the device or parts thereof.
• Destruction of additional components such as motor, machine, etc.
• Electrical shock to the human body.

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Customer handbook AC-Servocontroller DAC deltadrive

2. General information

2.1 The deltadrive Group

Various companies have joined together under the name “The deltadrive Group” for the
purpose of developing, producing and marketing state-of-the-art digital AC drives.

2.2 Short description of the deltadrive

The deltadrive 3-phase converter offers a modular drive concept for servo motors with sine-
wave conduction and encoder feedback.
deltadrive can be utilized as a control device for synchronous machines with sine-wave
commutation and for asynchronous machines with field-oriented vector control. The customer’s
application determines the choice of motor. The fully digitized 3-phase control device enables
direct connection to the 230VAC mains. We recommend the use of interference suppression
filters.
The basic model of the deltadrive is equipped with encoder feedback. This allows the use of
synchronous and asynchronous motors. A digital input allows you to switch from automatic
speed control to position control and vice versa. This allows, e.g. the use of the drive as the
main drive with spindle positioning.
Up to 32 devices can be networked together (without repeater) over the RS485 interface. (With
repeater = 62 devices)
The device is equipped with 8 digital inputs and 8 digital outputs as well as 3 analog inputs and
2 analog outputs. Numerous applications can be implemented by insertion of the FB 100
optional card (functional board) equipped with an additional 4 digital inputs and 8 digital power
outputs (2A), encoder analysis and the RS 232 interface. Inputs and outputs can be
programmed with the help of application software.
Configuration, start-up and diagnoses take place with the help of a PC user interface via the
standard RS-232 interface.
Operating condition and errors are displayed on LED’s located on the front of the device.
Analog signals such as programmed speed, power and actual speed are digitized and
processed by the microprocessor.
An adaptive control algorithm ensures on line that the deltadrive is constantly being adjusted
for any temperature dependent parameters.
A real-time multitasking operating system and the high resolution of speed signals enable a
considerable degree of control exactitude and dynamic. This in turn enables good speed
stability and torque linearity. This ensures reliable use in high-precision applications.
Additional applications - such as spindle positioning, indexing, winder with tension control,
electronic gearing and integration of entire customer applications in the drive - are in wide use.
For multi-axis operations the FBK 100 options card can be mounted in a drive. This makes an
on-line connection with the MMI (man-machine interface) unnecessary because the gateway
on the FBK 100 maintains communication with the controller at a rate of 340 kbaud. An RS-
422 interface communicates with the PC/MMI at a rate of 115 kbaud. Additional memory,
master encoder interpretation and a virtual encoder creation are other features of this
intelligent application card.

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deltadrive Customer handbook AC-Servocontroller DAC

2.3 Declaration of EU conformity

Declaration of EU conformity:

Declaration of conformity, specifically with the EU – EMC Guideline 89/336/ECC

We, STA STATE OF THE ART ENGINEERING AG

Dorfstrasse 38
CH- 6341 Baar
Switzerland

Switzerland

Declare under our sole responsibility that the product deltadrive

series model is exclusively intended for incorporation in another machine, and in conformity with the
provision of the following Council Directive: version 89/392/EEC and 93/68/EEC.

The following standards were referred to in assessing the product:

Standards for assessment of immunity to noise or disturbance:

• EN 50082-2 5/95 EMC – Basic standard for interference immunity, industrial area

Standards for assessment of radiated interference:

• EN 50081-2 8/93 EMC – Basic standard for interference immunity, industrial area
• EN 55011 93 Limiting values and test measurement procedures for radio interference from high
frequency industrial devices

Copyright © STA STATE OF THE ART ENGINEERING AG 2001. All rights reserved.

Reproduction, transfer, distribution or storage of part or all of the contents in this document in any form
(printed, photocopied, microfilm or in any other process), or processed or reproduced by use of any
electronic system, without the specific prior written permission of STA STATE OF THE ART
ENGINEERING AG is strictly prohibited.

STA STATE OF THE ART ENGINEERING AG, operating under the deltadrive Group other product and
company names mentioned (R&D Deltadrive Phils Inc., Otto Bartholdi AG Motoren) herein might be
trademarks or tradenames of their respective owners.

STA STATE OF THE ART ENGINEERING AG operates a policy of continuous development. STA
STATE OF THE ART ENGINEERING AG; reserves the right to make any changes and improvements to
any of the products described in this document without prior notice.

The contents of this document are provided “ as is”. Except as required by applicable law, no warranties of
any kind, either express or implied, including, but not limited to, the implied warranties of merchantability or
contents of this document.
STA STATE OF THE ART ENGINEERING AG reserves the right to revise this document or withdraw it
any time without prior notice.

This declaration should not be implemented as guaranteeing characteristics.

The security specifications of the manual are to be observed in all cases.

Declaration by the Company Management

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Customer handbook AC-Servocontroller DAC deltadrive
Messrs. Robert Ritter / Markus Schneider

Baar, 05-29-2002 Signature:

Signature:

This declaration should not be construed as guaranteeing characteristics. The security

specifications of the handbook are to be observed in all cases.

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deltadrive Customer handbook AC-Servocontroller DAC

3. Device description

3.1 Technical data

(Valid for environmental temperatures up to 40 °C max.)
Nominal data DAC 03 DAC 05 DAC 08 DAC 016 DAC 030
Nominal AC voltageUN VAC 1x or 3x 80 - 230 +max. 10%, 50/60 Hz
Nominal AC power WN kVA 1.0 1.8 2.8 5.5 10.0
System fuse (FF) all devices individually A 10 10 10 35 50
Maximum power (t=60s) kVA 1.8 3.3 4.6 9.0 15.0
Maximum power (t=5s) kVA 2.5 4.8 6.5 13.0 22.0
Rated output voltage V 3x 0 .. 200V, max. 0.87UN, 0 .. 800 Hz
Short circuit & ground fault-protection yes
Nominal output current IN Aeff 3 5 8 16 30
Maximum current (t=60s) Aeff 4.3 7.1 11.3 22.5 42.0
Maximum current (t=5s) Aeff 6 10 16 32 55
Internal braking resistance Ω - 39 39 30 13
Braking power (t=5s) kW - 3.5 3.5 5 9.5
Continuous braking power kW - 0.5 0.5 1.0 1.5
Working voltage for engaging brake V 370
Intermediate circuit voltage VDC 110 - 360
Clock frequency of output stage kHz 8
Residual voltage drop at nominal power V 4
Quiescent dissipation power W 20 20 20 25 25
Dissipation power at nominal current (no brake W 55 80 115 220 385
resistance)

Inputs
Analog-inputs, res 10bit (Option 14bit) V ± 10
Common mode voltage - max. V ± 25
Input resistance kΩ 70
Digital-inputs V 0 .. 24 (Switch threshold 10V)
Common mode voltage - max. V ± 25
Auxiliary voltage supply VH (UN = 0V) V 24
Power consumption PH W 8 8 8 12 12

Outputs
Analog-outputs, resolution 8bit V ± 10
Output current - max. mA 50
Digital outputs V 0 .. 24
Output current - max. mA <200
Digital power outputs (external supply) V <60
Output current - max. A 2

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Customer handbook AC-Servocontroller DAC deltadrive
3.1.1 Acceptable environment, ventilation, housing

Environmental temperature: 0 .. 40oC

Storage temperature: -25 ... +85oC
Humidity class: F DIN40040
Protection type: IP 20 DIN40050, IEC144
Installation position: vertical (see sec. 3.2)
Ventilation: free convection
take care to provide sufficient (forced) air
ventilation in a closed switch cabinet

3.1.2 Conductor cross section

In accordance with EN 60204 Part1, or VDE 0113 we recommend the following conductor
cross sections:
DAC 03 .. 08 DAC 016 DAC 030
mains connection 1.5 mm2 2.5 mm2 4.0 mm2
(plug X2) (e.g. ACO powerflex (e.g. ACO powerflex (e.g. cabloflex
CY 4x1.5mm2) CY 4x2.5mm2) C 4x4.0mm2)
protective ground >10mm2
(sec. 4.5.10) (leakage converter current
>3.5mA VDE 160 par.6.5.1.2)
motor connection same cable as mains connection
(plug X1)
external 1.5 mm2 2.5 mm2
braking resistance (e.g. ACO colorflex LI sw) (e.g. ACO colorflex LI sw)
encoder connection paired, shielded
(plug X6) (e.g. ACO colorflex CY-UL 4x2x0.14mm2 or 7x2x0.14mm2)
analog set value 0.5 mm2
(plug X5, X7) (e.g. ACO powerflex CY 3x0.5mm2)
control signal 0.25mm2
(plug X5, X7) (e.g. ACO colorflex 0.25mm2)
network connection 4 poled standard modular cable
RS 485 with EMC ferrite core
(plug X3, X4)
PC-connection null-modem link cable RS232 (FB100/101/102)
RS 232 or RS 422 or RS 422 - RS 232 adapter (FBK100)
(plug X10)

3.1.3 Fusing

Mains connection: as per table 3.1, page 8. The use of 30mA fl-circuit breakers is not
possible due to the leakage current (up to100mA) of the converter.
Motor connection: electronically fused, shortcircuit and ground-proof
Braking resistance: electronically fused
Control inputs: not fused
Control outputs: not fused

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deltadrive Customer handbook AC-Servocontroller DAC

3.1.4 LED displays

deltadrive contains a self-diagnosis and monitoring system that reacts to numerous errors that
can occur during operation. Most errors are displayed on the front of the deltadrive on the
LED display.

LED 2 green (speed =0) LED 1 yellow (brake active)

LED 3 green LED 0 red
(address = number
of blinks)

LED 7 green (controller on) LED 4 red (Rap halt)

LED 6 green LED 5 yellow
(controller ready) (controller in current limits)

diagram 1

LED display condition (LED on) LED display error (LED blinking)
controller ready, LED 6 on computer initialising
speed = 0, LED 2 on LED 1 blinking

Station address, LED 3 blinking error on starting processor

(number of blinks = address) LED 1,5 blinking
LED 2,6 on
controller on, LED 7 on DC bus link voltage too low or
power section on missing
LED 2,6 on LED 0,1,5 blinking
speed <> 0, Motor turning DC bus link voltage too high
LED 7,6 on (check braking power)
LED 1,4,5 blinking
brake active, LED 1 on speed too high
generator operation LED 4,5 blinking
LED 7,6 on
current limit reached Encoder error
LED 5 on (check connection)
LED 7,6 on LED 0,4,5 blinking
Rap halt, LED 4 on controller too long in current
motor stopped limits
LED 2,6 on LED 0,5 blinking
position discrepancy error
LED 5 blinking

application error
LED 0,1,4 blinking

IGBT error (error in power

section)
LED 0,1,4,5 blinking

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Customer handbook AC-Servocontroller DAC deltadrive

3.2 Dimensions

>=100mm
A D

H B
DAC 03/05 DAC 08

E
deltadrive deltadrive
δ δ

F C

M3

M4

K G L >=300mm

K >=100mm

deltadrive
DAC 016 δ
DAC 030 Dimensions in mm

A minimum space of 100 mm above and

below must be observed for air ventilation.

M3

M4

diagram 2

Device type A B C D E F G H K L Weight

DAC 03 60 205 208 260 25 222 30 5 65 15 2.7 kg
DAC 05 60 205 208 260 25 222 30 5 65 15 2.9 kg
DAC 08 60 205 208 250 25 222 30 5 95 15 4.6 kg
DAC 016 70 205 208 250 25 222 30 5 100 20 5.2 kg
DAC 030 70 205 208 250 25 222 30 5 100 20 5.5 kg

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deltadrive Customer handbook AC-Servocontroller DAC

3.3 Front view showing service features and connections

DAC 08/FB100 DAC 08/FBK100

Signal - LEDs
ready for operation X11 FB100 D-SUB 44f
Display of status and
• additional encoder X11 FBK100 D-SUB 44f
error.
• 4 digital inputs • additional encoder
• 8 power outputs • parallel port
• Multiturn absolute encoder • daisy chain download
X5 plug 14 pol.
for connection to the
X10 D-SUB 9m
signal cable
• RS 232-interface
(not activ at fast network)
X3, X4 plug modular X10 RJ 45
for RS 485 interface • RS 422-interface
X7 D-SUB 44f
• 8 digital inputs
• 8 digital outputs
X2 plug 10 pol. • 4 analog inputs
for power connections • 2 analog outputs
• auxillary (external) supply
• 3 „high speed“ inputs see diagram 3

X1 plug 4 pol.
for motor connection X6 D-SUB 15f
• encoder connection

see diagram 3

diagram 3 diagram 4

DAC 016/FB100

see diagram 3

see diagram 3

screw clamps
for power connections
and motor connection
see diagram 3

see diagram 3

diagram 5

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Customer handbook AC-Servocontroller DAC deltadrive

4. Assembly and wiring

4.1 General guidelines

Inspection of new unit

After unpacking the deltadrive or before assembly and operation, examine the unit for signs of
possible damage in transit.
Check the deltadrive’s name plate against the shipping documents and your original order.

Wiring guidelines
The following tips should help you avoid wiring problems. They are intended as guidelines.
Shielding and interference suppression:
Control signal cables should be shielded and normally should be grounded at both ends.
Twisted-pair cables within the outer shielding should also be shielded individually if their length
is more than 5 meters.
Power cables should be shielded and the shielding grounded at both ends. Never use cables
of too narrow a gauge because the skin effect puts uneven loads on small-diameter wires
cable.
To comply with EMC regulations (EU directive 89/392/EEC) we recommend ferrite cores on all
cables.
To avoid interference the cables should be laid in two groups (power, controls). These groups
should be separated or laid in different channels. Keep the cables as short as possible (cable
length > 20m ask the manufacturer).
The two groups:
• Power system (motor cable, mains cable, DC bus, etc.)
• Control system (encoder, control signal, control supply, etc.)

If devices incorporating power stage electronics are installed in or near switching/control units
or attached to the same mains, precautions should be taken to avoid interference in the
switches.
• Inductive coils, switching devices and relay combinations should be operated with RC
circuits or diodes.
• Sources of interference (power circuits, protective control circuits, etc.) are to be separated
and installed well away from the control circuits.
• In general we recommend the use of an auto transformer to adjust the voltage from
3x400VAC to 3x230VAC for the deltadrive power supply.
• We recommend noise suppression filters for critical applications.

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deltadrive Customer handbook AC-Servocontroller DAC

4.2 Connector pin assignment

For cable selection please observe the recommendations for the conductor cross section in
Sec. 3.1.2

4.2.1 Motor connection (plug X1)

DAC 03 - 08 DAC 016 - 030

4 poled plug connector - 1 PE prot. earth PE 1

orange multipoint con- PHOENIX -
2 U2 U2 2 printclamp type
nector with cage tension
drawspring type WAGO 3 V2 Motor V2 3 FRONT 4..-6,35
231-304/026-000 4 W2 W2 4

diagram 6

4.2.2 Mains an DC bus connection (plug X2)

DAC 03 - 08 DAC 016 - 030

1 A+
2 A+ A+ 1
10 poled plug DC-bus
3 D- D- 3
connector - orange
4 D-
multipoint connector F 5 PHOENIX -
5 F ext.brake resistance
with cage tension printclamp type
U1 6
drawspring con- 6 U1 FRONT 4..-6,35
nection type WAGO mains V1 7
7 V1
231-310/026-000 8
8 W1 W1
9 PE PE 9
prot. earth
10 PE

diagram 7

4.2.3 Network connection RS485 (plug X3 and X4)

X3 Modular cabling with 4 poled modular plug

system. Cables are available as
X4 accessories.

deltadrive 1 deltadrive 2 deltadrive n

diagram 8

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Customer handbook AC-Servocontroller DAC deltadrive
4.2.4 Signal connection (plug X5)

1 AD+
Analog prgramm’d
2 AD- speed value
3 GND
4 Drive on
5 Enable
Control inputs
6 Raphalt
7 GND
14 poled plug connector - Grey multipoint
8 Operate
Control outputs connector with cage tension drawspring
9 Ready
connection type WAGO 231-114/0026-000
10 +24V Supply outputs
11 P1 Computer
12 SGND auxilliary power
13 + Station number or
14 - PTC thermistor

diagram 9

4.2.5 Encoder connection (plug X6)

deltadrive Encoder
D-Sub 15f with UVW/TAM
Signal Pin No. Color
A+ 1 blue/black
1 A+ 6 U+ 11 A- A- 11 blue
2 NP+ 7 U- 12 NP- B+ 3 green
3 B+ 8 V+ 13 B- B- 13 green/black
4 GND 9 V- 14 +5V NP+ 2 yellow
5 GND 10 W+ 15 W-
NP- 12 yellow/black
+5V 14 red
GND 4 black
5
U+ 6 brown
U- 7 brown/black
V+ 8 grey
diagram 10
V- 9 grey/black
W+ 10 white
15 poled female plug D-SUB on the W- 15 white/black
deltadrive, pin contact (male) on the
cable.

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deltadrive Customer handbook AC-Servocontroller DAC

4.2.6 Signal connection (plug X7)

Signal Sign. Pin No.
Analog AD1+ 1
input 1 AD1- 16
GND 31
Analog AD2+ 2
input 2 AD2- 17
1 AD1+ 16 AD1- GND 32
31 GND
2 AD2+ 17 AD2-
32 GND Analog AD3+ 3
3 AD3+ 18 AD3-
33 GND input 3 AD3- 18
4 PTC+ 19 PTC-
34 Earth GND 33
5 HS1+ 20 HS1-
35 HS2
6 E0 21 O0 PTC resistor PTC+ 4
36 GND
7 E1 22 O1 motor PTC- 19
37 24V
8 E2 23 O2 Ground 34
38 GND
9 E3 24 O3
39 GND Analog DA1 14
10 E4 25 O4
40 +5V output 1 GND 29
11 E5 26 O5
41 +15V Analog DA2 15
12 E6 27 O6
42 -15V output 2
13 E7 28 O7 GND 30
43 +24V
14 DA1 29 GND Digital inputs E0 6
44 GND
15 DA2 30 GND E1 7
E2 8
E3 9
E4 10
E5 11
E6 12
E7 13
diagram 11 Common GND 39
reference
High speed HS1+ 5
44 poled female plug D-SUB on the deltadrive input 1 HS1- 20
pin contact (male) on the cable. High speed HS2 35
input 2 GND 36
Digital O0 21
outputs O1 22
O2 23
O3 24
O4 25
O5 26
O6 27
O7 28
ext. supply. 24V 37
Supply +5V 40
(WARNING +15V 41
power total < -15V 42
4W!)
+24V 43
GND 44

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4.2.7 Options connection FB100 (plug X11)

Signal Sign. Pin No.

Additional A+ 1
encoder A- 31
NP+ 2
16 U+ NP- 32
1 A+ 31 A-
2 NP+ 17 U- B+ 3
18 V+ 32 NP-
3 B+ B- 33
19 V- 33 B-
4 GND 34 5V 5V 34
5 GND 20 W+ GND 4
21 HS3- 35 W-
6 HS3+ 36 24V shield 5
7 24V 22 0V
23 0V 37 IN12 U+ 16
8 O8 38 GND
24 0V U- 17
9 O9 39 IN13
10 O10 25 0V V+ 18
26 0V 40 GND
11 O11 V- 19
27 0V 41 IN14
12 O12 42 GND W+ 20
13 O13 28 0V
43 IN15 W- 35
14 O14 29 0V
30 GND 44 GND Digital inputs IN12 37
15 O15 IN13 39
IN14 41
IN15 43
GND 38
GND 40
GND 42
diagram 12 GND 44
High speed HS3+ 6
input HS3- 21
44 poled female plug D-SUB on the deltadrive Digital O8 8
pin contact (male) on the cable. outputs O9 9
O10 10
O11 11
O12 12
O13 13
O14 14
O15 15
ext. supply 24V 7
36
0V 22..29

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deltadrive Customer handbook AC-Servocontroller DAC

4.2.8 RS-232 interface PC connection (plug X10)

5 GND
9 RI
4 DTR 9 poled male plug D-SUB on the
8 CTS
3 TXD deltadrive
7 RTS
2 RXD female on the link-cable
6 DSR
1 DCD

diagram 13

4.2.9 Options connection FBK100 (plug X11)

Signal Sign. Pin No.
Additional A+ 1
encoder A- 31
NP+ 2
NP- 32
B+ 3
1 A+ 16 U+
17 U- 31 A- B- 33
2 NP+ 32 NP- 5V 34
3 B+ 18 V+
19 V- 33 B- GND 4
4 GND 34 5V
5 GND 20 W+ shield 5
21 W- 35 GND
6 GND 36 Error U+ 16
7 GND 22 GND U- 17
23 Data 0 37 SLCT
8 GND 38 PE V+ 18
9 SCLK 24 Data 1
25 Data 2 39 ACK V- 19
10 GND 40 Busy
26 Data 3 W+ 20
11 MODE 41 Store
12 lspEN 27 Data 4 W- 35
28 Data 5 42 Autofxdt
13 SD1 Parallel Port Data 0 23
29 Data 6 43 IMT
14 SD0 44 SLCTIN Data 1 24
15 GND 30 Data 7
Data 2 25
Data 3 26
Data 4 27
Data 5 28
Data 6 29
Data 7 30
Error 36
diagram 14
SLCT 37
PE 38
44 poled female plug D-SUB on the deltadrive ACK 39
pin contact (male) on the cable. Busy 40
Store 41
Autofxdt 42
IMT 43
SLCTIN 44
GND 6,7,8
22,35
Daisy Chain SLCK 9
Download GND 10
MODE 11
lspEN 12
SD1 13
SD0 14
+5V 15

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Customer handbook AC-Servocontroller DAC deltadrive
4.2.10 RS - 422 interface FBK100 (plug X10)

8 DRVRED-
7 DRVRED+
6 DRVACK- 8 poled RJ-45 plug on the deltadrive
5 DRVACK+
4 RXD-
3 RXD+
2 TXD-
1 TXD+

diagram 15

4.2.11 Shielding connection

plate for tension relief

and shielding The side mounted bracket plate on the
DAC 03 - 05 serves the purpose of tension
relief and securing of the shielding.
cable to On the DAC 08 - 030 the shielding is fixed
supply to the heat sink with a clamp.
The shielding for the motor cable should
be grounded on both sides.

cable to
motor

diagram 16
4.2.12 Ground connection

deltadrive
The lead wire cross section of the
protective conductor to the cabinet must
be at least 10mm2 CU.
It is best to connect the protective
conductor close to the deltadrive.

Mounting tracks
Ground

diagram 17

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deltadrive Customer handbook AC-Servocontroller DAC

4.2.13 Interface module (plug X7 / plug X11)

The interface module simplifies the wiring of the signal connections on the X7 and X11 plugs It
is snapped into place on the DIN mounting tracks in the switchbox. The interface connection
cable for the deltadrive can also be supplied.

Interface module plug X7:

Digital inputs with power

clamps for direct connection High speed digital inputs with
of sensor in 3-wire system power clamps for direct
connection of sensor in 3-wire
system

Auxiliary deltadrive power

Status indicator for outputs.
digital inputs. Only CAUTION! Maximum
functions with loads must be observed!
deltadrive connected (Total <4W)

Status indicator for high

Station address speed digital inputs
encoding (optional)

Dirrerential, analog
inputs Connection for X7
deltadrive plug

Status indicator for

digital outputs Ground
connection

Grounding and
shielding connection Clamps for digital
outputs' external
power supply
Analog outputs

Clamps for digital

inputs' external power
supply

Digital control outputs with 0V

clamps for connection of
actuator in 2-wire system

diagram 18

CAUTION! Make sure plugs are connected properly to the deltadrive.

Electronic systems will be damaged if the X7 and X11 plugs are
interchanged

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Customer handbook AC-Servocontroller DAC deltadrive

Interface module plug X11:

Digital inputs with power for

clamps for direct connection
of sensor in 3-wire system High sped digital input with
power clamps for direct
connection of sensor in 3-wire-
system
Encoder connection
Input

Satus indicator for digital

Encoder connection inputs. Only functions with
Output deltadrive connected

DIP-Switch for +5V Status indicator for high

encoder current speed digital inputs
(external or internal)

Connection for X11

deltadrive plug
Status indicator for
digital outputs
Ground and shielding
connection
Ground
connection
Clam ps for digital
outputs' external
power supply

Clam ps for digital

inputs' external power
supply

Digital control outputs with 0V

clamps for direct connection of
actuator in 2-wire system

diagram 19

CAUTION! Make sure plugs are connected properly to the deltadrive.

Electronic systems will be damaged if the X7 and X11 plugs are
interchanged

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deltadrive Customer handbook AC-Servocontroller DAC

4.3 Arrangement of jumpers

Must only be checked if assignments differ from the configuration for the customer's
application (see table on p. 23).

JP104 JP102 Processor board

viewed from
X6
component side
JP201 CPU1
JP105 JP103

JP203
JP204
JP206
JP202
X7

JP205
JP101 3
3 2 1 JP209 2 JP302/303
1
Optional FB100 card Optional FBK100 card
X10
X10

JP403 JP101
JP308
X11 1 X11
2 CPU2 JP402
3
JP405 JP301 JP401
JP401JP402 JP404 1 2 3 JP100
DIP

diagram 20

Power board
viewed from above

Connected:
3 4

JP701 JP801 1 2
JP702

Power board

diagram 21

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Customer handbook AC-Servocontroller DAC deltadrive
Table of jumper arrangement:
Jumper Standard Customer Function
configuration configuration
JP101 2-3 connected 1-2 connected Power output connected to internal 24 VDC supply
JP102 connected Development (ext. / int. memory access)
JP103 connected not connected External GND connected to internal GND
JP104 connected Encoder shielding connected to internal GND
JP105 connected Internal 5 V DC current for encoder connected
Processor board DAC 100

JP201 connected ADC1 bipolar (input voltage ±10V max.)

JP202 not connected Option for ADC 1/2
JP203 connected ADC2 bipolar (input voltage ±10V max.)
JP204 not connected ADC2: connected. / n. con. ⇒ input voltage. ±2.5V / ±10V
JP205 connected ADC3 bipolar (input voltage ±10V max.)
JP206 not connected ADC3: connected. / n. con. ⇒ input voltage. ±2.5V / ±10V
JP301 connected Development (ext. / int. memory access)
JP302 connected Internal bus terminator for network active
JP303 connected Internal bus terminator for network active
JP308 2-3 connected RS232 - interrupt DSR / RI
JP209 2-3 connected Autom. Station address detection / PTC resistor
JP701 not connected Network supply +5 VDC not connected
Power-
board

JP702 not connected Network supply GND not connected

JP801 connected GND connected to PE

JP401 connected Internal 5VDC supply for encoder connected

FB 100 card

JP402 connected External GND connected to internal GND

JP403 connected not connected Control inputs' GND connected to internal GND
JP404 connected not connected Outputs' GND connected to internal GND
JP405 1-2 connected External 24VDC for outputs connected
JP401 connected External 5VDC supply for encoder connected
FBK 100

JP402 connected External GND connected to internal GND

card

JP100 not connected Processor reset inactive

JP101 not connected FBK programming mode inactive

4.3.1 Rearranging the jumpers

The controller housing must be opened to reset the jumpers. This should
only be done in consultation with the supplier; otherwise, any and all claims
under the warranty become null and void.

The deltadrive controller can be disassembled as follows:

• After removing the front panel, detach the heat sink baseplate from the controller housing
by removing the 8 screws. The electronics module can then be carefully separated from the
housing.
• The electronic components on the printed circuit board may not be touched under any
circumstances.
• After removing the attachment screws the processor board should be carefully pulled away
from the connector.
• Set the jumpers correctly according to the project guide or configuration diagram and then
properly reassemble the controller.

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deltadrive Customer handbook AC-Servocontroller DAC

4.4 Switch settings

Switch No. Function

ON Low speed network

1
OFF High speed network
2,3 Not used
OFF
ON
Computer boots with operating system only,
ON
enable defective software to be reinstalled.
4
Computer boots with application software
OFF
active (normal operation)
5,6,7,8 Not used

Front panel

diagram 22

4.5 Automatic station address detection

For automatic station address detection, a station address button is inserted into pins 13 and
14 of the X5 plug instead of a PTC temperature sensor.
Table of resistance values
Station Resistance in
address ohms
1 0
2 1200
3 2200
4 3300
5 4700
6 5600
7 6800
8 8100
9 10000
10 12000
11 15000
12 18000
13 22000
14 27000
15 33000
16 39000

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Customer handbook AC-Servocontroller DAC deltadrive

5. Software installation
A servocontroller delivered with the standard features is only equipped with the basic software.
The software for the customer's specific facility therefore has to be loaded after the controller is
installed on-site. This requires an PC compatible computer with an RS232 interface and an
installed deltadrive IDE (Integrated Development Environment). In addition an RS232/422
interface converter is necessary with a connector cable for the deltadrive.

5.1 Software installation with the FBK100 card

• Connect plug X10 on the deltadrive to the PC's serial port (COM1 or COM2) using the
RS232/422 adapter.
• Feed 24V to controller at pin 11 (24V) of plug X5 and pin 12 (GND).
• Start the program DELIDE1.EXE (Windows 3.11 or Windows 95).
• Load an existing project with the machine number (e.g. HZX1-4.prj) from the diskette using
the icon or the File, Open Project menu.
• Select Load Project to Drives using the icon or the Loader menu. (The application software
has now been installed and saved on all controllers.)
• After the files have been loaded, quit the program using File, Exit.
• Important! Now turn off the machine using the main switch and wait 2 minutes. Then turn
on the main switch again. The machine is ready for operation.

diagram 23

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deltadrive Customer handbook AC-Servocontroller DAC

6. Servicing

Assuming a dust / free installation, no particular servicing is required for the deltadrive.
Nevertheless, and to ensure the product’s safe performance at all times, we recommend
periodic servicing of your deltadrive.
The examples below should be taken as recommendations. You should determine and
undertake the necessary periodic service work on the basis of the application and location.

Servicing on your deltadrive should only be performed by trained professionals

who observe the security and safety specifications.

The main switch or the system fuses should be switched off before any servicing.
• We recommend periodic opening of the air slits in the controller housing depending on the
degree of cleanliness (or dirt) in the area of the deltadrive.
• The control cabinet should be checked occasionally for the recommended operating
temperature.
• Check connections periodically.
• Check the motor and deltadrive for any unusual noises.

7. Trouble-shooting

7.1 Servomotor problems

7.1.1 Encoder-fails setup check
If the setup check of the encoder is unsuccessful, the encoder has to be recalibrated. The
motor will have to be returned to the factory for this purpose.

7.1.2 Blocked motor

When the controller is switched off, it should be possible to turn the motor by hand. If this is not
the case there must be a mechanical problem, either in the power train (gearing, connecting
flange etc.) or in the motor. If the defect is in the motor, it will have to be returned to the factory
for repairs.

7.2 Problems with the deltadrive-controller

7.2.1 Communications check
If it is impossible to establish connection with the deltadrive please check the following:
• If you are using an FBK100 card, verify correct connection of the RS422/232 adapter to
plug X10 on the deltadrive and to the COM1 or COM2 port of the PC.
• Make sure the software driver has been correctly written into your config.sys. The following
line must be included:
DEVICE=C:\DELTA\FDLDRV6.SYS PORT=1, STAD=32H, NET=1
(PORT=1 for COM1; PORT=2 for COM2; NET=1 for high speed network; NET=0 for low
speed network)

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Customer handbook AC-Servocontroller DAC deltadrive
• The station address has to be consistent with the address indicated by the number of blinks
at LED3 when the deltadrive is switched on. The station address button must be inserted
on pin 13, 14 of plug X5.
• Parameter checks with the MONITOR.EXE program: If the parameters are displayed,
communications are in order. If the parameters window displays the "neterror" message
and the station address is correctly indicated by LED3, the cable connection to the PC has
to be checked again. (Caution! Leave the MONITOR.EXE program only with the "Alt-X" key
combination.)

7.2.2 Controller doesn't start

After the deltadrive's mains power supply is switched on, the two green LED2 and LED6
indicators should light up. If no LEDs or other LEDs light up, turn off the controller and try
again. If the results are the same, the controller has to be replaced.

7.2.3 LEDs blinking on controller

In this case the condition or error indicated by the displays can be determined using the table
in section 3.2.4 on page 10.

7.2.4 Motor starts turning immediately

If the motor starts turning as soon as the deltadrive is switched on, please check the following:
• Encoder connection
• The phases of the motor must be connected in the right order (for BAC and SAC motors the
sequence is as follows: motor UVW = controller WVU; cf. diagram 24).
• The parameters may be incorrectly configured. Please also make sure that the motor
parameters compatible with the motor have been entered in the controller.
• If all these measures fail to correct the situation, the controller must be replaced.

7.2.5 Motor vibrates

If the motor starts vibrating after the controller is ready, please check the following:
• The motor parameters compatible with the motor must be loaded into the controller.
• The phases of the motor must be connected in the right order.
• The controller parameters must be correctly set for the specific application (e.g. too high
amplification of speed regulator).
• Check motor for short circuit in the coil (by measuring phase resistances) and for ground
fault.

7.2.6 Motor "whistles"

If the motor emits a high-pitched tone after the controller is ready, please check the following:
• The amplification of the current regulator should not be set too high.

7.2.7 Analog inputs and outputs not functioning

The analog inputs and outputs are only operational when the 220V mains supply to the
controller is switched on. The analog inputs and outputs cannot be used with the computer's
auxiliary power supply.

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deltadrive Customer handbook AC-Servocontroller DAC

8. Connector assignments for customer's application

Input Assignment X7 No. X5 No.
AD1+ 1 1
AD1- 16 2
Shield 31 3
AD2+ 2
AD2- 17
Shield 32
AD3+ 3
AD3- 18
deltadrive Shield 33
δ PTC+ 4 13
PTC- 19 14
Ground 34
Plug X5 Output Assignment X7 No. X5 No.
DA1 14
GND 29
DA2 15
GND 30
Output Assignment X7 No. X5 No.
E0 6 4
E1 7 5
Plug X7 E2 8 6
E3 9
E4 10
E5 11
E6 12
E7 13
G2 39 7
Input High speed assignment X7 No. X5 No.
HS1+ 5
HS1- 20
HS2 35
GND 36
Output Assignment X7 No. X5 No.
O0 21 8
O1 22 9
O2 23
O3 24
O4 25
O5 26
O6 27
Application O7 28
P2 37 10
Output Assignment X7 No. X5 No.
Customer
GND 29...33, 3
36,38,44
Project +5V 40
+24V 43
Date +15V 41
-15V 42
Author Power X7 No. X5 No.
P1 11
Initialled P1GND 12

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Customer handbook AC-Servocontroller DAC deltadrive

8.2. Additional inputs and Outputs (plug X11)

Input Assignment X11 No.

E12 37
E13 39
deltadrive
E14 41
δ Plug X11 E15 43
GND 38 + 40
42 + 44
Input High speed assignment X11 No.
HS1+ 6
HS1- 21
Output Assignment X11 No.
O8 8
O9 9
O10 10
O11 11
O12 12
O13 13
O14 14
O15 15
0V 22
23..29
24V 7 + 36

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9. Three phase synchronous motors

9.1 Frame type references

SAC 118 M 20 / 3 / TB / E Y -2 0 4 8 /..

TYPE
SAC / BAC

fra m e s iz e
70
90
118
145
195

c o re le n g th
K
S
M
L

s p e e d [m in -1 ]
1200 - 12
2000 - 20
3000 - 30
4500 - 45
6000 - 60

o p e ra tin g v o lts
300 V - 3
500 V - 5

c la m p b o x
fo r p o w e r
c o n n e c tio n

o p tio n s
/../..

9.2 Options
BR standard brake
BS brake with increased braking torque
provision for:
EA adaptor for ROD 426 encoder
EB encoder type 35, 2048 Imp./min-1
EC adaptor for ROD 426 encoder with cover
EY-2048 Encoder with rotor position detection; resolution 2048ppr
FT special flange finish in accordance to din 42955 class R
IP enclosure ip 67
NK shaft without key
PA special paint finish to ral
SE special shaft extension
SS oil seal at drive end
TH thermistors (without monitoring unit)
VS balance to class s to din/iso 2373

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Customer handbook AC-Servocontroller DAC deltadrive

9.3 Datasheet SAC 118M20

Encoder connection see diagram 10

diagram 24

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deltadrive Customer handbook AC-Servocontroller DAC

9.4 Datasheet SAC 90L20

Encoder connection see diagram 10

diagram 25

Page 32 Customer handbook 05-2002