DAC Drives

Service Manual
Sercos Version

Code: 45006847X
Rev. 00

PUBLICATION ISSUED BY:

OSAI S.p.A.
Via Torino 14, 10010 Barone Can.se (Italy)

Copyright  2000 by OSAI

All rights reserved

Edition: June 2000

IMPORTANT USER INFORMATION

This document has been prepared in order to be used by OSAI. It describes the latest release of
the product.
OSAI reserves the right to modify and improve the product described by this document at any time
and without prior notice.
Actual application of this product is up to the user. In no event will OSAI be responsible or liable for
indirect or consequential damages that may result from installation or use of the equipment
described in this text.
ABC
 Preface
DAC Drives

PREFACE

Abbreviations

AMP Adjustable Machine Parameters

CPU Central Processing Unit
DAM Digital Axis Module
DSI Digital Service Channel
DSM Digital Servo Module
DSP Digital Signal processor
DSV-6 Digital Servo V-6 controller
EEPROM Electrically Erasable Programmable Read Only Memory
IDN IDentification Number
LED Light Emitting Diode
PE Protective Earth
PSU Power Supply Unit
SERCOS SErial Realtime COmmunication System
SW SoftWare

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Preface
DAC Drives

END OF PREFACE

2 DAC Drives – Service Manual (00)

 Contents
DAC Drives

INDEX

SAFETY INFORMATION
PRELIMINARY NOTES............................................................................................ 1-1
ASSEMBLY.............................................................................................................. 1-2
INSTALLATION AND COMMISSIONING................................................................. 1-2

DIAGNOSTICS
DIAGNOSTIC TOOLS.............................................................................................. 2-1
Display and Local LED’s on the Modules ........................................................ 2-1
Messages Displayed on the CNC Monitor....................................................... 2-1
Error Code in the IDN S129 Parameter........................................................... 2-1
LOCAL DISPLAYS AND LED’S ON THE MODULES .............................................. 2-1
H20 Display .................................................................................................... 2-2
H47 Display .................................................................................................... 2-2
H21.2 LED...................................................................................................... 2-2
H22.2 LED...................................................................................................... 2-2
H43(G) and H44(G) LED’s.............................................................................. 2-2
H43(R) and H44(R) LED’s .............................................................................. 2-2
MESSAGES DISPLAYED ON THE CNC MONITOR ................................................ 2-3
Errors Recognized by the CNC. ...................................................................... 2-3
Errors Recognized by the Drive and Transmitted to the CNC ......................... 2-4
ERROR CODE IN THE IDN S129 PARAMETER...................................................... 2-7
Error Code Table ............................................................................................ 2-7

MODULAR DRIVE
MODULAR SYSTEM PRINCIPLE ............................................................................ 3-1
DSV-6 CONTROLLER ............................................................................................. 3-2
Front Panel..................................................................................................... 3-2
LED Display.................................................................................................... 3-3
DSM POWER UNIT.................................................................................................. 3-4
Connections ................................................................................................... 3-4
Error Messages .............................................................................................. 3-6
PSU POWER SUPPLY UNIT ................................................................................... 3-7
Connections ................................................................................................... 3-7
Error Messages .............................................................................................. 3-9

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Contents
DAC Drives

BUB BRAKING MODULE ........................................................................................ 3-10

Connections ................................................................................................... 3-10
LED Indications .............................................................................................. 3-11
BUR BRAKING RESISTOR ..................................................................................... 3-12
Connections ................................................................................................... 3-12
BUL INDUCTOR MODULE ...................................................................................... 3-13
Connections ................................................................................................... 3-13

DAM 60 DRIVE
Connections .................................................................................................... 4-1
LED Display.................................................................................................... 4-2

ACCESSORIES
BFN FILTER MODULE ............................................................................................ 5-1

REPLACING MODULES
SETTING THE DAM 60 MODULE AND THE DSV-6 CONTROLLER....................... 6-2
Hardware Setting............................................................................................ 6-2
Software Setting ............................................................................................. 6-2
SETTING UP THE PSU MODULE............................................................................ 6-3

END OF INDEX

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 Chapter 1
SAFETY INFORMATION

PRELIMINARY NOTES

The device was designed on the basis of the latest technology and ensures safe operation. It can
be installed and put into operation without any risk and provides trouble-free operation so long as
the safety indications given in this chapter are respected.

Failure to respect these safety instructions and warnings may result in serious injury to persons
and/or damage to the products in question.

Any servicing required by this equipment is to be performed exclusively by qualified staff. Qualified
staff is intended to mean persons who have the qualifications required to carry out their activities
and who have considerable experience in finalizing, assembling, setting up and operating the
product. They are trained, instructed and authorized to put the machine into operation and to earth
circuits and devices in compliance with the approved safety regulations. The machine supervisor
must guarantee that no unauthorized person is allowed access to the machine.

During operation, some contacts are powered with dangerously high voltage (500 - 800 VDC). This
voltage requires more than one minute after power-off (disconnection from the power network) to
drop below the danger limit. The voltage may be measured between the external contacts of the
bus. Before any maintenance work may be carried out on the drives, make sure that the voltage is
no longer present.

The plastic covers on the connections of the PSU and DSM modules serve as a supplementary
protection, by preventing accidental contact with the powered parts.

Failure to make the PE (protective earth) connections on the equipment or on the motor may cause
serious injury to persons and/or serious damage to the products in question.

The equipment may only be put into operation on earthed electrical networks.

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Chapter 1
Safety Information

ASSEMBLY
The user is held responsible for assembling the unit, the motor, and any other components in
compliance with the safety regulations. At the same time, it must be guaranteed that all other
national and local directives are respected with regard to the power and protection of the cables,
the earth connection, remote control switches, overcurrent protection, etc.

Protect the drives against excessive mechanical loads. Avoid contact with the electronic contacts.

Check that the cooling air flow is not blocked by obstacles inside or outside the equipment and that
there is sufficient space above and below the device to prevent overheating.

The drives comprise components sensitive to electrostatic discharge. Before touching the modules,
in particular, the contacts of electronic connectors, discharge any electrostatic charge from your
body to protect the electronic components against the high voltages resulting from the electrostatic
charge. The easiest way of doing this is to touch an earthed conducting object, before touching the
modules.

INSTALLATION AND COMMISSIONING

Before commissioning the machine, make sure that the plastic covers on the power connections of
the PSU and DSM modules are in the closed position, and are fixed with the screws.

Great attention must be paid before touching the motor shaft with your hands. This operation is
only allowed when the system is powered down and the motor is at a standstill.

When disassembling safety devices during the commissioning procedure, or repair or maintenance
work, make sure that the machine is deactivated in compliance with the applicable directives.
Reassemble and check the safety components immediately after commissioning, repair or
maintenance work.

During the initial phase of commissioning, an incorrect or uncontrolled movement of the motor-
driven elements may occur. Consequently, during this phase, proceed with extreme caution.

Before turning on the drive, check the functions of all external safety devices carefully to prevent
injury to persons. The safety devices must never be disabled.

The electrical control boxes must be equipped with elements for deactivating any voltage that could
prove dangerous. The emergency device must be located in such a way that it can be quickly
reached in case of danger. If extremely dangerous jobs are to be done, another person must be
present.

END OF CHAPTER

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 Chapter 2
DIAGNOSTICS

DIAGNOSTIC TOOLS

Display and Local LED’s on the Modules

They are present on the DAM 60 and DSV-6 modules. They provide indications on the status of the
drive and the SERCOS interface. A more detailed description is provided in this chapter.

Messages Displayed on the CNC Monitor

They are listed in this chapter.

They can be recognized directly by the CNC, or received from the drives, decoded and shown on
the display. Each error received from a drive is assigned an error code which can be read using the
SERCOS parameter (IDN) S129.

Error Code in the IDN S129 Parameter

By reading the IDN S129 parameter, and using the error code table (see later in this chapter), you
can obtain further details about the nature of the error and any solutions available.

LOCAL DISPLAYS AND LED’S ON THE MODULES

For the position of these devices, see the chapters on the various modules.

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Chapter 2
Diagnostics

H20 Display
At power-on, it displays 0 for about 1 second. After this time, if no errors have occurred in the drive,
it displays 1.
If an error occurs, it displays E.
About 3 seconds after the power connection, if the “rapid halt” signal is 24V, it displays 2.
With the drive enabled, it displays 4.
Depending on the machine logic, the switch from status 1 to 4 may take place directly, if a time of
less than 3 seconds passes after the power connection.

H47 Display
At power-on, it displays 0, until the CNC starts to initialise the SERCOS system. During the
initialisation phase, it displays the phases 1, 2, 3 and 4. During normal operation, it displays 4.

During the initialisation procedure, if an error is detected, the CNC shows the corresponding error
message while the H47 LED shows the phase number during which the error occurred:
0: Probable breakage of the ring, incorrect connection of the optical cable, distortion of the signal
on the cable, incorrect transmission speed.
1: The configuration of the CNC in the AMP environment does not correspond to the physical
configuration of the network. (Example: Incorrect drive address)
3: Failure of a drive to respond

H21.2 LED
This LED lights up when the drive limits the current output, which may be a sign of an excessive
load on the corresponding axis. If this LED lights up immediately after the drive is enabled, it may
be due to incorrect connection of the motor’s power cable or transducer cable.

H22.2 LED
It must light up during the initialisation phase after power-on, and remain on during the operation of
the machine. If it goes off, it indicates an error inside the drive.

H43(G) and H44(G) LED’s

When they are both on, they indicate that the SERCOS system is working properly.

H43(R) and H44(R) LED’s

When they are both on, they indicate that communication on the SERCOS system has been
aborted.

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 Chapter 2
Diagnostics

MESSAGES DISPLAYED ON THE CNC MONITOR

Note: The term “encoder 1” identifies the transducer connected to the X24 connector, while
“encoder 2” identifies the transducer connected to the X25 connector.

The error messages referring to the drives may be of the following 2 types:

• Recognized by the CNC

• Recognized by the drive

Errors Recognized by the CNC.

These are typically optical fibre connection errors.

Code and Message Description Corrective action

EE040 Over signal Excessive distortion of the signal Check the integrity and
distortion on optical on the optical fibre. connection of the optical fibre
fibre

Turn the machine off and on

again.

EE041 Interrupt The signal on the optical fibre was

transmission on interrupted. Check the integrity of
optical fibre the optical fibre cable and the If the problem persists, call the
connections. engineering service.

EE042 AT Telegram Cyclic data communication with

missing the D.S.I. driver failed.

EE043 D.S.I. Initialization Error during the initialisation Check the address of the drive
phase error phase. and the speed of transmission.

EE044 Anomaly on Error during the transmission of Check the integrity and
service channel commands from the Master to the connection of the optical fibre
D.S.I. driver
Execute a system RESET.

EE045 Anomaly on D.S.I. Error during the execution of a Execute a system RESET e
command command. eliminate the cause of the error.
execution

EE048 D.S.I. Fault: Fatal error, during the Turn off the system and call the
anomaly during management of an error caused engineering service.
anomaly by the drive.

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Chapter 2
Diagnostics

Example, how the message appears on the screen:

Code: EE041 Process: 0

Interrupt transmission on optical fibre
Phase number: 0

Errors Recognized by the Drive and Transmitted to the CNC

The error code is shown on the display by a bit set to 1 in a 16 bit word.
The number of the bit is identified as indicated in the table below:

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

There are 2 types of error:

• Fatal errors (emergency)

• Non-fatal errors (“warnings”)

• Fatal errors (Class 1 diagnostic)

Code and Message Description Corrective action

EE046 Drive shut down: "Class 1 diagnostic" error See the documentation of the
class 1 coming from the drive. D.S.I. drive
diagnostic

Example, how the message appears on the screen:

Code: EE046 Process: 1

Drive shutdown: class 1 diagnostic
Phase number: 5 Axis: X
Anomaly code: 0000000000100000

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 Chapter 2
Diagnostics

Error codes in class 1 diagnostic:

Bit number (15-0) Error code in the S129 (IDN) parameter

Meaning

15 0203, 0206, xxxx

Indicates one or more of the following errors:
Power supply error (PSU)
Blocked motor
EEPROM error
Operating system error
Drive error
11 0601, 0602
Excessive position error
8 0201, 0205
Bus overvoltage, or
Overtemperature of the power group
7 0202
Overcurrent
6 0207 … 020D
Power transistor error
5 0300 … 0304, 0800 .. 0808, 0A00 … 0A08
Error in encoder 1 (X24) and/or encoder 2 (X25)
4 0204
Interference on the 24V power supply
2 0501
Motor overtemperature
0 0401
Software motor temperature protection

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Chapter 2
Diagnostics

• Non-fatal errors (Class 2 diagnostic)

Code and Message Description Corrective action

EE047 Shut down Non-fatal error indication coming See the documentation
warning: class 2 from the "class 2 diagnostic" D.S.I. provided with the D.S.I.
diagnostic driver. drive.

Example, how the message appears on the screen:

Code: EE047 Process: 1

Drive shutdown: class 2 diagnostic
Phase number: 5 Axis: X
Anomaly code: 0000000000000100

Bit number Meaning

(15-0)

15 Parameter 495, bit 15

------
2 Parameter 151, bit 7
Motor overtemperature
1 Parameter 115, bit 6
Power supply temperature > 80°C
0 Parameter 93, bit 4
Software protection: motor temperature > alarm level (P088)

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 Chapter 2
Diagnostics

ERROR CODE IN THE IDN S129 PARAMETER

The table below lists the error codes that may be read using the IDN S129 parameter. The
contents of the IDN S129 parameter may be deleted by executing the SERCOS command S099.
For this function, use the COMMAND command in the DIAGNOSTIC \ DSI SRV CHAN
environment.

Error Code Table

• Drive CPU errors

Error code Description Meaning Solution

0001 Internal drive Contact the engineering
0002 communication errors service
0003
0004
0005 System start-up An error occurred when the start-up Check the drive parameter
procedure data was read from the EEPROM. This settings carefully and then
error normally occurs when the SW save them to the
present in the drive system is replaced EEPROM.
with an incompatible SW
Alternatively, contact the
engineering service
0010 Drive program error Contact the engineering
service

• Drive Power Supply Errors

Error code Description Meaning Solution

0110 Problems in the power The “ready for use” signal from the Check the power supply
supply unit power supply unit is missing. (PSU module).
Reset the error in the
power supply unit (see
also the PSU section.)
If the error occurs in the
DAM 60, contact the
engineering service.

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Chapter 2
Diagnostics

• Drive Power Unit Errors

Error code Description Meaning Solution

0201 Bus overvoltage The bus voltage has exceeded the Inspect the braking
value of 800 V ± 1%. It may indicate an resistor
internal drive error or excessively short Contact the engineering
and/or frequent braking cycles service
0202 Overcurrent Average current output value too high Adjust the current ring
parameters (P080, P081)
0203 Error current Current error in the current loop too Check the motor cables for
high leakage to earth
0204 Problems in the supply There is no power supply to control the Check the safety relay
of auxiliary voltage. transistors in the power unit control (if present).
Contact the engineering
service
0205 Overtemperature in the The temperature of the power unit has Wait for the temperature to
power unit exceeded 85 °C. drop below 85 °C (P118)
0206 Problems in the safety The safety relay of the power unit is Check the safety relay
relay OFF even though it should be ON. This control (if present).
means that the supply of auxiliary Contact the engineering
voltage for controlling the transistors is service
deactivated.
0207 Transistor error Error caused by UCE too high in one or Check the motor cables for
0208 upper U phase more power transistor due, for a short-circuit or leakage
0209 lower U phase example, to a short-circuit, leakage to to earth. Let the power unit
020A upper V phase earth or due to a defect in the cool down. If the problem
020B lower V phase transistor. persists, replace the power
020C upper W phase unit.
020D lower W phase
020E Unknown power unit The control unit does not recognize the Contact the engineering
identifier identifier read service
020F Power unit of an The type of power unit saved does not Contact the engineering
incorrect type correspond to the one read by the service
system.
0210 Problems in the power The ready to use signal from the power Contact the engineering
unit unit is missing. service

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 Chapter 2
Diagnostics

• Encoder Errors

Error code Description Meaning Solution

0301 Runaway speed of The control has detected an actual Inspect the encoder cable.
encoder 1 speed value (P023) higher than the Check the controller speed
runaway speed (P046). setting
0302 Runaway speed of The encoder has detected an actual Inspect the encoder cable.
encoder 2 speed value (P243) higher than the Check the controller speed
runaway speed (P239). setting
0303 Unknown absolute The error occurs in the following cases:
position of encoder 1 1. During the initialisation of the
encoder it was not possible to read
the absolute position of the encoder
(e.g. due to module of the encoder
adapter, due to the lack of
communication)
0304 Unknown absolute 2. The encoder has no information
position of encoder 2 about its absolute position (e.g.
incremental encoders with
sinusoidal or square wave signals

• Motor Status Errors

Error code Description Meaning Solution

2 2
0401 motor control I t Calculated I t (P091) is greater than Leave the drive disabled
2
100% (software protection) until the actual I t value
(P091) drops below 100%.
0501 Motor overtemperature The thermal sensor indicates an Let the motor cool until its
excessive motor temperature temperature has dropped
below the maximum value.
Inspect the connection and
status of the thermal
sensor.

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Chapter 2
Diagnostics

• Position and Speed Control Errors

Error code Description Meaning Solution

0601 Dynamic position error With the machine in motion, e.g. during Check the error limit
positioning, the position error (P210) setting and, if necessary,
has exceeded the error limit (P203). correct it. Reset the
enabling of the position
error in parameter P201,
bit number 0.
0602 Static position error With the machine at a standstill (e.g. Check the static error limit
when the arrival position has been setting and, if necessary,
reached), the error (P210) has correct it. Reset the
exceeded the error limit (P212). enabling of the error in
parameter P201, bit
number 1.
0702 Blocked motor During the blocking time set in P056, Check the machine for a
the motor has remained stationary, with mechanical obstacle
maximum torque.
Check the power
connection of the motor
(also the sequence of the
phases)
Check the motor encoder
connection.

• Errors in Encoder 1 (Connected to the X24 Connector)

Error Code Description Meaning Solution

0801 Invalid module code The code of the adapter module is Check the type of adapter
unknown
0802 Incorrect adapter The encoder adapter in the unit is not Change the setting in the
module suitable for the type of encoder encoder mode or use
required and the communication another adapter
protocol settings
0803 No communication with The encoder cannot read the absolute Inspect the encoder cable
the encoder position. on the motor side and the
unit side
0804 Break in wiring of The encoder signals are not valid Inspect the encoder cable
encoder 1 on the motor side and the
unit side

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 Chapter 2
Diagnostics

• Driver Parameter Management Errors

Error code Description Meaning Solution

0901 EEPROM read/write error. The error may only be
corrected by turning off the
drive. If the error occurs
frequently, this means that
there is a defect in the drive.
0902 Start-up parameter setting The start-up parameters are not present in The valid set of parameters
lost EEPROM (area 0 of EEPROM) must be created in the RAM
and then saved in the
EEPROM
0903 Checksum error in start-up During the check of the start-up parameters, The valid set of parameters
parameters the system calculates an incorrect must be created in the RAM
checksum value. and then saved in the
EEPROM

• Errors in Encoder 2 (connected to the X25 connector)

Error code Description Meaning Solution

0A01 Invalid module code The module code of the adapter is Check the type of adapter
unknown
0A02 Incorrect adapter The adapter of the encoder in the unit Change the setting in the
module is not suited to the type of encoder encoder mode or use
required and the communication another adapter
protocol settings
0A03 No communication with The encoder cannot read the absolute Inspect the encoder cable
the encoder position. on the motor side and unit
side
0A04 Break in wiring of The encoder signals are not valid Inspect the encoder cable,
encoder 2 on the motor side and unit
side

• Drive Operating System Errors

Error code Description Meaning Solution

0B01 CPU timing error Error in timing the various programs of P160 select = 0,
the drive CPU
0B02 P169 value = 0, Save the
data flow again and reset
0B03 the error

0B04 DSP time exceeded. Contact the engineering

service

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Chapter 2
Diagnostics

END OF CHAPTER

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 Chapter 3
MODULAR DRIVE

MODULAR SYSTEM PRINCIPLE

D SM
P rotective cover driver unit

P S U Power supply unit C onnector

D SV -6
C ontrol U nit

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Chapter 3
Modular Drive

DSV-6 CONTROLLER

Front Panel
F A S TE N IN G S C R E W
G U ID E

H20

H21
H22
X 23

X 26

X 27

X 25

F0 1
E
2 3
BC D

4 5

6
789 A

X 24

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 Chapter 3
Modular Drive

H 4 3 (G )
H 4 3 (R )

H 4 4 (G )

H 4 4 (R)
®
H 4 3 (G ) A N D H 44 (G ) O N : P H AS E 4 , C O R R E C T O P E R A TIO N
H 4 3(R ) O R H 44(R ) O N : C O N N E C TIO N A BO R T ED

H 4 7: 7 -SE G M E N T D ISP LA Y : IN D IC A T E S T H E S E R C O S P H A S E S
0
EF 1
O F TH E D R IVE
2 3
B C D

45

67

P O W E R -O N : 0-1 -2-3-4
89 A

S 48 A D D R ES S S E LEC T O R

S 49: TR A N SM IS S IO N S P E E D
1 : O N : 4 M B A U D O FF : 2 M BA U D
2 : R ES E R VE D

X 46: O U TP U T (O P TIC A L F IB R E C A B LE )

X 45: IN P U T (O P T IC A L F IB R E C A B LE )

LED Display
Meaning of the H21 and H22 LED’s.

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Chapter 3
Modular Drive

DSM POWER UNIT

Connections

D SM D SM D SM D SM

P rotective
covers

D SV -6

S upport panel
assem bled on the wall
of the control box.
The D S M is hooked
onto this panel

DVS 6 control unit

ord ered and delivered
sep ara tely.

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 Chapter 3
Modular Drive

E ncoder

U V W PE
Bus +
Bus -
PS U
pow er + 24 V PS U 6
supply u nit + 24 V pow er
or 0 V supply u nit
0 V or
D SM R eady for use by PS U
drive m odule. D SM 6
R iserve
drive m odule.
X 9 9 A: X 9 9 B:

C onnector for D S V-6

N O T E: D raw ing w ithout

protective c overs.

NOTE:
The DSM module requires no setting.
A cable for connecting X99A (B) and 2 bus bars for connecting BUS+ and BUS- are provided with
the DSM.

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Chapter 3
Modular Drive

Error Messages
The following faults may occur in the DSM module, and generate an error message:

• Overcurrent
The motor current in the motor phases is monitored and if the phase current exceeds the
allowed peak current, an overcurrent message is generated

• Earth fault
An earth fault message is generated when the leakage current exceeds the peak current of the
DSM module by 10 %.

• High-voltage bus overvoltage

If the voltage level of the high-voltage bus reaches 800 V, an error message is generated.

NOTE:
The voltage of the high-voltage bus may increase if the drive brakes and the power of the
braking resistor is not sufficient.

• Power transistor overcurrent

If an excessively high saturation voltage is detected in the conductive state, this means that
there is an overcurrent in the power transistors, for example, following a short-circuit in the
motor terminals, and a controlled stop is activated, turning off the transistor and generating an
error message.

• Auxiliary voltage fault

• Heat sink overtemperature
The heat sink has a linear thermal sensor which transmits the measurements to the DSV-6
control unit.

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Modular Drive

PSU POWER SUPPLY UNIT

Connections

PSU PSU

P rotective
covers

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Chapter 3
Modular Drive

N et 400 V ± 10% , 50/60 H z

L1 L2 L3 PE
N L1 F0
L3 L2 L1
F1
D1
K1
F3
F2
L1 2W 1 2V1 2U 1

X1 5 4 3 2 1

1U 1 1V1 1W 1
B us +
B us -
+ 24 V
R e a d y fo r u s e
(c o nta c t clo s ed ) + 24 V
DSM
0V
Alarm D rive
(contact open) 0V M o dule
R eset
C lear error R ea dy for u se
m em ory
(contact closed) R es erv e

X 99A : X 99A B: X 99B :

N O TE : Draw ing without

protective covers

NOTE:
The PSU module does not require any setting

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Modular Drive

Error Messages
The following faults may occur on the PSU module, generate an error message and open the
“ready for use” relay:

• Overcurrent
If the line current exceeds the allowed peak current by 30%, an overcurrent message is
generated.

• High-voltage bus overvoltage

The system generates a message if the high-voltage bus voltage exceeds 800 V.

• Power transistor overcurrent

If an excessively high saturation voltage is detected in the conductive state, this means that
there is an overcurrent in the power transistor; this may be due, for example, to a short-circuit
on the motor terminals.

• Auxiliary voltage too low

• Power or phase failure
This function opens the “ready for use” relay if at least one phase of the mains power fails. If the
bus voltage drops below 500 VDC, the “prealarm” relay opens (X99 AB : 3,4).

• Heat sink overtemperature

In case of an overload, that is, if the temperature of the heat sink exceeds 90° C, the control
device opens the “prealarm” relay ( X99 AB : 3,4).

After ten seconds, the “ready for use” relay opens.

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Modular Drive

BUB BRAKING MODULE

Connections

N O T E : D ra w in g w ith o u t
p ro te ctive c o ve rs

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LED Indications
The LED’s on the front of the module have the following meanings.

LED Function / cause

READY Voltage present on the high-voltage bus ( > 200V)

(Bus active)
LOAD Braking resistor is activated. (Operation correct)
The motor is charging the bus, during a braking cycle. If the voltage of the
bus reaches 750 V, the braking resistor is connected to the bus, and when
the voltage drops below 730 V, the resistor is disconnected from the bus.
OVERLOAD Error indication.
The resistor activation time is too long for the cycle time.
(Normal setting: activation time of ~ 20 s for a complete cycle time of 90 s)
This function may be disabled using contact I5.
TEMP Error indication
Heat sink overtemperature (>85°C)
LOAD ERROR Error indication
Overcurrent caused by incorrect sizing of the braking resistor.

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Chapter 3
Modular Drive

BUR BRAKING RESISTOR

Connections

N O T E : D ra w in g w ith o u t
p ro te ctiv e co v e rs

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 Chapter 3
Modular Drive

BUL INDUCTOR MODULE

Connections

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Chapter 3
Modular Drive

END OF CHAPTER

3-14 DAC Drives – Service Manual (00)

 Chapter 4
DAM 60 DRIVE

Connections
Conn ectio n voltage 3x4 00 V B+ B- PE
L1 L2 L3

I> I> I>

B rake
M
δ

U V W
D ischarge tim e
> 1 m inute
12
X 1U 2
1
1V 2
1W 2

1U 1
1V 1
1W 1
BA-
R B int. 3)
ZK +
ZK -
1
X5 -
2
+
24 V DC
1

0
EF 1
2
B CD

345

67
89A

3) If there is an external ballast resistor, remove the bridge between X1:3 and X1:4

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Chapter 4
DAM 60 Drive

H 4 3 (G )
H 4 3 (R )
H 4 4 (G )

H44 ® (R)
H 4 3 (G ) A N D H 44 (G ) O N : P H AS E 4 , C O R R E C T O P E R A TIO N
H 4 3(R ) O R H 44(R ) O N : C O N N E C TIO N A BO R T ED

H 4 7: 7 -SE G M E N T D ISP LA Y : IN D IC A T E S T H E S E R C O S P H A S E S
0
EF 1
O F TH E D R IVE
2 3
B C D

45

67

P O W E R -O N : 0-1 -2-3-4
89 A

S 48 A D D R ES S S E LEC T O R

S 49: TR A N SM IS S IO N S P E E D
1 : O N : 4 M B A U D O FF : 2 M BA U D
2 : R ES E R VE D

X 46: O U TP U T (O P TIC A L F IB R E C A B LE )

X 45: IN P U T (O P T IC A L F IB R E C A B LE )

LED Display
Meaning of the H21 and H22 LED’s

A LED display, which provides additional information, is situated below the seven-segment display.

END OF CHAPTER

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 Chapter 5
ACCESSORIES

BFN FILTER MODULE

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Chapter 5
Accessories

END OF CHAPTER

5-2 DAC Drives – Service Manual (00)

 Chapter 6
REPLACING MODULES

NOTE:
While maintenance work is being carried out, the single drive modules must not be opened.
All faulty modules must be replaced and sent to the factory for repair.

The following modules require a hardware and/or software setting during the commissioning phase:

• DAM 60
• DSV-6
• PSU

The DAM 60 module is replaced completely. The electronic part cannot be removed and replaced
on its own

On the contrary, when a fault occurs on the DSV-6 controller, which is inserted in the DSM power
module, it is replaced without having to replace the whole DSM module. The DSV-6 controller is
fixed by 2 screws (see the drawing in the relevant section). To remove the module, first unscrew
the 2 screws and then remove the module. To assemble it, simply perform the inverse procedure:
insert the DSV-6 drawer in the DSM module, using the plastic guide, present in its upper part.
When the rear connector of the drawer touches the connector on the DSM, insert the connector
carefully, by pressing slightly onto the drawer. Complete assembly by fixing the drawer with the 2
screws.

The DSV-6 is a separate module, which is identified by its own commercial code, and is
ordered and delivered separately. It is not part of the DSM module!

When working on the electrical control box, take care in handling the optical fibre cables. In
particular, the radius of curvature must not be less than 30 mm.

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Chapter 6
Replacing Modules

SETTING THE DAM 60 MODULE AND THE DSV-6 CONTROLLER

The DAM 60 module contains the power group and an electronic unit which is also used in the
DSV-6 controller. This uniform feature enables the same setting procedure to be carried out for the
DAM 60 drive and the modular drive which contains the DSV-6 controller.

Before removing the faulty module from the electrical control box, make sure that the configuration
file of the relevant drive is present on the CNC. If it is not, the file must be created using the SAVE
AX INFO command in the DIAGNOSTIC / DSI SRV CHAN environment.

Hardware Setting

• SERCOS address of drive

Locate the S48 rotary selector, positioned on the front panel (see the drawing in the
corresponding section). The selector must be set to the number that corresponds to the address
of the drive.

• Transmission speed
Locate the S49 two-way selector, positioned on the front panel (see the drawing in the
corresponding section). Selector N° 1 must be set to the position that corresponds to the
transmission speed used by the SERCOS interface.

If no changes are made to the CNC configuration file with regard to the addresses and/or
speed, the same S48 and S49 settings as those used on the replaced module are made on the
new module.

At the time of publication of this document, the standard position of the S49 / 1 selector
corresponds to 2 Mbaud, OFF position, left. The S49 / 2 selector is not used by the drive. (The
ON position of the selector is indicated by the arrow printed both on the drawing and on the
selector itself).

Software Setting
The software setting of the DAM 60 and DSV-6 modules consists in transferring the parameters
present in the configuration file of the corresponding axis. We recommend the transfer be made in
phase 2 of the CNC, by carrying out the following procedure.

• Execute emergency power-on

Having replaced the module and made the hardware settings, all the connections must be made
again and the control box (24 VDC) must be powered on, by activating the CNC in emergency
mode (by holding the F1 key pressed during power-on).

• Activate lock in phase 2

Activate the CNC lock in phase 2, by specifying 1 in the CFG DSI SETUP command in the DSI
REBOOT CFG environment. Exit using the EXIT command and activate the REBOOT SYSTEM
command. At this point, the CNC is restarted, and stops in phase 2. The number “2” appears on
the H47 display of all drives.

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 Chapter 6
Replacing Modules

• Download parameters from the CNC to the drive

In the DIAGNOSTIC / DSI SRV CHAN environment, execute the LOAD command and
download from the CNC disk the configuration file of the drive that has just been replaced. The
configuration downloading procedures takes a few minutes. Once completed, save the
parameters on the drive, using the relevant commands of the Service Channel.

• Start the CNC in the ordinary way

Power off and on again in emergency mode. In the DSI REBOOT CFG environment, execute
the DATA RESTORE command.

• Start the system with the new drive

Exit using the EXIT command and execute the REBOOT SYSTEM command. At the end of
start-up, the main screen appears on the CNC and “4” appears on the H47 display of all drives.

SETTING UP THE PSU MODULE

The PSU has to be connected to the three-phase power network, respecting a given sequence of
the three phases. As the phase sequence is not known, it may not be respected when the
connection is made for the first time. In this case, the bus level does not reach the rated level (640
VDC), but remains at a lower level, approximately 560 VDC, and the “ready for use” relay does not
close. The problem is solved by swapping any two of the wires of the cable leading to the mains.

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Chapter 6
Replacing Modules

END OF CHAPTER

6-4 DAC Drives – Service Manual (00)