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Summary of Contents for Bosch DM**8001 Series
- Page 1 Antriebs- und Steuerungstechnik Servodyn-D Frequency Inverters DM..8001 (ASM) Parameter and Commissioning Manual Edition...
- Page 2 Parameter and Commissioning Manual 1070 066 028-101 (01.05) GB E 2001 by Robert Bosch GmbH, Erbach, Germany All rights reserved, including applications for protective rights. Reproduction or distribution by any means subject to our prior written permission. Discretionary charge DM 10.–...
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Page 3: Table Of Contents
Contents Contents Page Safety Instructions ......1–1 Intended use ......... . . 1–1 Qualified personnel . - Page 4 Contents Series Commissioning ......6–1 Edit and load *.asd file ........6–1 Couple next drive .
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Page 5: Safety Instructions
Safety Instructions 1–1 Safety Instructions Please read this manual before commissioning the modular DM..8001 fre- quency inverters of the Servodyn-D series. Store this manual in a place to which all users have access at any time. Intended use This manual contains information required for the intended use of this pro- duct. -
Page 6: Qualified Personnel
Safety Instructions 1–2 Qualified personnel The requirements as to qualified personnel depend on the qualification pro- files described by ZVEI (Zentralverband Elektrotechnik und Elektronikin- dustrie – German Electrical and Electronic Manufacturers’ Association) and the VDMA (Verband deutscher Maschinen- und Anlagenbau – German En- gineering Federation) in: Weiterbildung in der Automatisierungstechnik edited by: ZVEI and VDMA... -
Page 7: Safety Markings On Products
Safety Instructions 1–3 Safety markings on products Warning of dangerous electrical voltage! Electrostatically sensitive components! Warning of hazardous light emissions (optical fibre cable emitters)! Lug for connecting PE conductor only! Connection of shield conductor only 1070 066 028-101 (01.05) GB... -
Page 8: Safety Instructions In This Manual
Safety Instructions 1–4 Safety instructions in this manual DANGEROUS ELECTRICAL VOLTAGE This symbol is used to warn of a dangerous electrical voltage. The fail- ure to observe the instructions in this manual in whole or in part may result in personal injury. DANGER This symbol is used wherever insufficient or lacking compliance with in- structions may result in personal injury. -
Page 9: Safety Instructions Concerning The Product Described
The consequences may include severe injury, damage to equipment, or environmental hazards. Possible retrofits or modifications to the system using third-party equipment therefore have to be approved by Bosch. DANGER Health hazards through destroyed electrical components! Do not destroy any built-in components. Dispose of destroyed com- ponents in a proper manner. - Page 10 5 minutes until the system is de-energized before removing any covers. The drive must always be examined for safe isolation from supply! CAUTION Use only spare parts approved by Bosch! CAUTION Observe all precautions for ESD protection when handling modules and components! Avoid electrostatic discharge!
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Page 11: Documentation, Software Release And Trademarks
Safety Instructions 1–7 Documentation, software release and trademarks Documentation The present manual provides information on the commissioning of the DM..8001 (ASM) frequency inverters of the Servodyn-D series. Overview of available manuals: Manuals Part no. German English French Italian Configuration 1070 066 009 1070 066 029 1070 066 059 1070 066 049... - Page 12 Upon delivery, all installed software is copyright-protected. The software may only be reproduced with the approval of Bosch or in accordance with the license agreement of the respective manufacturer. MS-DOSr and Windowst are registered trademarks of Microsoft Corpora- tion.
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Page 13: Prerequisites For Commissioning
Prerequisites for Commissioning 2–1 Prerequisites for Commissioning The installation and operation of the DSS requires general knowledge of the Windows user interface (e.g. start/exit programs, open/save files, change program windows, etc.). In the present manual, we suppose that this knowledge is available. CAUTION Commissioning by insufficiently qualified personnel may cause severe damage to the machine and drives or even personal injury! -
Page 14: Checking The Hardware
Prerequisites for Commissioning 2–2 Checking the hardware First make sure that the system is switched off and de-energized. Check the nameplates and the engineering documents for the proper in- verter type and the correct motor installed. Do not continue the commissioning procedure unless the correct hardware has been installed! Follow the instructions below step by step. -
Page 15: Operation At The Inverter
Operation at the Inverter 3–1 Operation at the Inverter Operator interface Every DM..8001 (ASM) frequency inverter is equipped with: D a keypad with three keys, and D a three-digit 7-segment display. D an RS 232 interface for connecting a PC, to be operated via the DSS Diagnostics and Service System. -
Page 16: Functions Of The Keypad
Operation at the Inverter 3–2 Functions of the keypad The 3 keys of the keypad provide for 4 functions. They ensure complete handling and optimization of the module: The ’Display’ key serves to jump to the lower next Display display level. This key has storage functions for parameter values, it must be depressed before returning to a higher level. -
Page 17: Displaying Operating Data
Operation at the Inverter 3–3 Displaying operating data Basic display Computer booted, temperature display, status display (see Section 2.1) Depress “D” key. Select display functions . . . Operating data A or parameter list PL1...PL8. Change Depress “D” key. Select element Select the desired display from the A00 ... -
Page 18: Changing Parameters
Operation at the Inverter 3–4 Changing parameters Basic display Computer booted, temperature display, status display (see Section 2.1) Do not activate enable signal! Depress “D” key. Select display functions . . . Status displays A or parameter list PL1...PL8. Only the list predefined on terminal block X06.5–7 may Change be selected. -
Page 19: Dss User Interface
To avoid communication faults between the PC and the drive, please note the following: D We recommend using the pre-assembled Bosch connection cable, part no.: 1070 077 753, length 5 m D Distance between connection cable – power cables: at least 20 cm. - Page 20 DSS User Interface 4–2 Configuring the interface Switch on the 24V supply of the system. Switch on the PC. Wait until the operating system has been fully booted and start the ”DSS” commissioning and service system. The ”Establish connec- tion” dialog is automatically displayed: This dialog may also be invoked manually when the connection has been successfully established: D menu sequence EXTRAS "...
- Page 21 DSS User Interface 4–3 Reinitializing DSS after module change or after parameter changes on the module If, while DSS is running, you D disconnect the connection cable from the inverter (e.g. for starting up a new drive), or D want to change parameters via the keyboard on the currently connected inverter, you then have to re-initialize the DSS.
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Page 22: Dss Basic Image
DSS User Interface 4–4 DSS basic image The layout of the DSS user interface has been optimized for a screen resolution of 640 x 480 pixels in connection with a 14” color monitor. You should not use screen resolutions of more than 800 x 600 pixels unless you have at least a 17”... - Page 23 DSS User Interface 4–5 Status bar current interface (COM1, 2) current axis number parameter currently or last transferred current drive phase transmission activity display ”Overview” window The ”Overview” window shows a single-line diagram of the entire system. The meaning of the command buttons is also displayed when the mouse pointer is on the command button.
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Page 24: Dss Monitor
DSS User Interface 4–6 DSS monitor The DSS monitor offers direct access to all parameters stored in the drive. You may: D edit parameters D save a list of several parameters as parameter file (*.asd). D transmit parameters to the drive. If parameters are changed directly on the inverter keyboard while the DSS is active, the DSS must first be reset afterwards. - Page 25 DSS User Interface 4–7 Representation of parameters: In the DSS At the inverter Configuration parameters A-0-0000...A-0-0049 P00...P49 Status displays A-0-1000 ... A-0-1015 A00 ... A15 3. Press <enter> or click on ”Get” button to read the parameter from the drive. If a parameter has been selected which has not been defined for the drive, an error will be displayed.
- Page 26 DSS User Interface 4–8 By clicking on the ”Import” command button, all parameters of this *.asd file are displayed in list format on the screen and can be modified in the ”Data” field. Current parameter Current parameter If active, clicking on value.
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Page 27: Module Status Display
DSS User Interface 4–9 Module status display The display will show dynamic information on D Current BTB1 warning: diagnostics message in plain text D actual values of max. 12 parameters D Last error after BTB2 was switched off. Select the menu sequence: D DIAGNOSES "... -
Page 28: Selecting The Language
DSS User Interface 4–10 Selecting the language The DSS user interface language may be changed over, but not the parame- ter and status texts. Language of user interface Select: EXTRAS " PREFERENCES Changing over the language To activate the new language, you have to reboot. 1070 066 028-101 (01.05) GB... -
Page 29: Save All Parameter Settings (Data Backup)
DSS User Interface 4–11 Save all parameter settings (data backup) It is urgently recommended to backup all relevant data when the parameters for a drive have been set. This data backup will be required to D efficiently perform series commissioning D restore a precisely defined drive status (e.g. - Page 30 DSS User Interface 4–12 Notes: 1070 066 028-101 (01.05) GB...
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Page 31: Commissioning
Commissioning 5–1 Commissioning DANGEROUS ELECTRICAL VOLTAGE Do not switch on the mains power unless the power supply has been connected and tested in accordance with section 2. When the unit has been switched on, all parameters are write protected. With the DSS and directly at the inverter, the parameters can only be viewed. In order to commission the system, you have to disable the write protection: When the inverter has booted (7-segment display = ”H”), press the boot key in the housing recess below the two LEDs with a pointed object. -
Page 32: Parameters
Commissioning 5–2 Parameters 5.1.1 Clock frequency The clock frequency can be adjusted in order to operate high-frequency spindles and to reduce noise and motor losses. P00 (A-0-0000) Clock frequency min. Range [Hz] max. smallest step 9.0 kHz DMs, DS > = 9 x f (P02) limits... -
Page 33: Output Frequency
Commissioning 5–3 5.1.2 Output frequency P01 (A-0-0001) Setting the output frequency range Selection of the working range which must comprise all further frequency settings. 1000 up to up to up to up to up to up to up to up to up to up to 1000 Hz... -
Page 34: Data On The Motor Rating Plate
Commissioning 5–4 5.1.3 Data on the motor rating plate The motor rating plate data must be entered as a standard. P04 (A-0-0004) Rated motor current I min. Range [A] max. DM 4K 9.5 A DM 8K 9.5 A DM/DS 15K 15.9 A DM 30K/A 31.8 A... - Page 35 Commissioning 5–5 P06 (A-0-0006) Rated motor voltage V The rated motor voltage V corresponds to the maximum output voltage (rms) of the inverter. The output voltage cannot exceed the line voltage. min. Range [V] max. smallest step 460 V DMs, DS factory setting P07 (A-0-0007)
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Page 36: V/F Characteristic
Commissioning 5–6 5.1.4 V/f characteristic The V/f characteristic serves to adjust the frequency inverter to the motor. The shape of the characteristic is determined by the input of the rated motor data. Furthermore, the type of characteristic and the information on I x R compensation must be selected. - Page 37 Commissioning 5–7 P08 (A-0-0008) Type of characteristic linear, I x R linear with with linear square-law with accel. torque boost torque boost DMs, DS factory setting P09 (A-0-0009) I x R compensation min. Range [% V max. smallest step 25.0 % DMs, DS factory setting...
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Page 38: Setpoint Ramps
Commissioning 5–8 5.1.5 Setpoint ramps The following parameters are available for the external and internal set- points: D simple braking ramp D simple acceleration ramp P11 (P48 = 0 Hz) D 2-step acceleration ramp P11, P48, P49 output frequency [Hz] resulting 2-step acceleration ramp acceleration... - Page 39 Commissioning 5–9 P49 (A-0-0049) Acceleration ramp up to frequency break point Range [sec] min. max. smallest step 999 sec DMs, DS factory setting P12 (A-0-0012) Braking ramp The braking time to be adjusted refers to braking from the maximum output frequency (P02) to f = 0.
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Page 40: Setpoint Adjustment
Commissioning 5–10 5.1.6 Setpoint adjustment P13 (A-0-0013) Setpoint source The frequency setpoint can be input using an external analog voltage or cur- rent signal or internally. The specified direction of rotation applies to properly connected motors when looking towards the shaft end. If an external voltage signal is used, 7 different setpoint smoothing options ) may be selected. - Page 41 Commissioning 5–11 P15 (A-0-0015) Adjustment f = f (Adjustment to maximum setpoint) Setpoint input X 23.5/6 can be adjusted in the range of $5...$13 V, setpoint input X 23.5/7 can be adjusted in the range of 10...27 mA. It is also possible to set a unipolar setpoint range: e.g., 0 ...
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Page 42: Current Limit
Commissioning 5–12 5.1.7 Current limit The admissible maximum current can be lower than the value selected via this parameter depending on the clock frequency and the heat sink temperature. The actual value is displayed via A11 ’Actual current limit’. P17 (A-0-0017) reduction in general min. -
Page 43: Emergency Braking
Commissioning 5–13 5.1.8 Emergency braking When the external enable signal FG has been deactivated, the drive is braked with the braking ramp selected via P12 until the output frequency f = 0 is reached. The braking ramp is extended if there is danger of exceeding I P19 (A-0-0019) Activate emergency braking Coasting... -
Page 44: Direct Current Braking
Commissioning 5–14 5.1.10 Direct current braking The frequency inverter generates a direct current in the motor windings in order to prevent uncontrolled deceleration and to build up a holding torque at zero speed CAUTION Frequent direct current braking may overheat the motor. The electronic bimetal function (P43 –... - Page 45 Commissioning 5–15 P22 (A-0-0022) Braking current The amount of the braking force or the holding torque at zero speed is determined by the braking current. If the braking current is higher, the motor heats up faster. Typical setting range: x rated motor current. min.
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Page 46: Suppression Of Resonant Frequencies
Commissioning 5–16 5.1.11 Suppression of resonant frequencies The suppression of resonant frequencies serves to suppress mechanical resonant sounds of the machine and thus to achieve smooth machine operation. A maximum of 3 frequency ranges can be suppressed. The center frequencies and bandwidths of the desired ranges must be entered in order to be able to pass these ranges as fast as possible using the selected acceleration and braking ramps. -
Page 47: Slip Compensation
Commissioning 5–17 5.1.12 Slip compensation The slip compensation serves to compensate for the speed drop between no-load speed and load speed (= slip). Slip compensation is maintained within a large speed range independent of load or the direction of rotation. Calculate setting value Enter the rated motor slip as a % value. -
Page 48: Stalling Warning
Commissioning 5–18 5.1.13 Stalling warning The stalling warning serves to recognize the danger of overload on an asynchronous motor. Before the motor is electrically stalled and stops, the frequency inverter outputs the“I ” 24 V signal at X13.3 as a stalling limit warning. - Page 49 Commissioning 5–19 P35 (A-0-0035) current limit up to f transition frequency 1max trans min. Range [A] max. DM 4K 9.5 A DM 8K 9.5 A DM/DS 15K 15.9 A DM 30K/A 31.8 A DM/DS 45K/A 47.7 A DM 85B 95.4 A 127 A 12.7 DM140D...
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Page 50: Frequency Warnings
Commissioning 5–20 5.1.14 Frequency warnings Three 24V outputs are available at terminal strip X34 for monitoring the output frequency: < f Provides for the definition of a reference frequency f . The module monitors the actual output frequency f for falling below this value. Monitors whether the actual output frequency f matches the frequency setpoint f... -
Page 51: Analog Outputs
Commissioning 5–21 5.1.15 Analog outputs Analog outputs X23.8 and X23.9 can be assigned the current operating data. For proper output signals, the rated motor power (P05) must be input. Level: 0 ... +10 V, Current and power signals can be adjusted within the following ranges (P41, P42): Assignment 10 V ¢... - Page 52 Commissioning 5–22 P41 (A-0-0041) Current standardization for total current (AA1), active current (AA2) and reactive current (AA3) min. Range [A] max. DM 4K 15.0 A DM 8K 15.0 A DM/DS 15K 25.0 A 15.9 DM 30K/A 50.0 A 31.8 DM/DS 45K/A 75.0 A 47.7 DM 85B...
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Page 53: Motor Protection Function
Commissioning 5–23 5.1.16 Motor protection function On the DM..8001 (ASM) you may alternatively choose between two motor protection functions: D Connection of a temperature sensor integrated in the motor winding head. D Activation of the electronic bimetal function which provides for thermal motor protection without an integrated temperature sensor. - Page 54 Commissioning 5–24 Release time I [A] P44 (A-0-0044) Release current constant The value to be adjusted must be obtained from the motor manufacturer. It is referred to speed-independent ventilation (’bF1’ characteristic). min. Range max. smallest step DMs, DS factory setting P45 (A-0-0045) Release time Range [sec]...
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Page 55: D.c. Link Control In The Event Of A Power Failure
Commissioning 5–25 5.1.17 D.C. link control in the event of a power failure If no line voltage is present, the frequency inverter maintains the d.c. link by using the kinetic motor energy, thus providing for safe braking up to motor zero speed. -
Page 56: Default Setting
Commissioning 5–26 5.1.18 Default setting The factory settings quoted for every parameter are replaced by individual optimization without getting lost. Using P46, all parameters of the current list can be reset to the factory settings. The values that have been optimized for specific needs are deleted. CAUTION Loss of data! The optimization data of the current parameter list get lost when se-... -
Page 57: Commissioning
Commissioning 5–27 Commissioning D All parameters have been checked and all necessary adjustments have been made according to Section 5.1. D Set setpoint selection to ’0’. D Activate enable signal. The basic operating display is shown. For a description, see Section 2.1. D Carefully increase setpoint. -
Page 58: Operation With Zero-Speed Control
Commissioning 5–28 5.2.2 Operation with zero-speed control Zero-speed control may serve as a protective function which can also be used if two identical motors are operated by one inverter. For activating zero-speed control, activate parameter P20. If the FG enable signal had been activated before, first cycle power to the unit, then activate P20. -
Page 59: Multiple-Motor Drive
Commissioning 5–29 Multiple-motor drive Several asynchronous motors with the same rated frequency and identical rated voltages can be operated simultaneously at one inverter. The motor power may be different. Please note: D The total motor power connected must not exceed the maximum output power of the inverter. - Page 60 Commissioning 5–30 Notes: 1070 066 028-101 (01.05) GB...
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Page 61: Series Commissioning
Series Commissioning 6–1 Series Commissioning During series commissioning, all data backed up with ’IDN Backup’ (cf. page 4–11) after initial commissioning of a drive are loaded to and saved in all other drives. If your application involves drives with different settings, parameters may be changed directly in the parameter file. -
Page 62: Couple Next Drive
Series Commissioning 6–2 3. The modified file may be transmitted to the drive, however, it has to be saved beforehand. Select the menu sequence: FILE " SAVE If the error ”Module1: Date of Axx currently write-protected” is dis- played during transmission, the write protection was not disabled by pressing the boot button (cf. -
Page 63: Firmware Update
For existing plants, a firmware update may be necessary in special cases. Your Bosch Service team will be pleased to advise you. The drive’s FEPROM will be cleared in the course of a firmware update! Therefore, you should make sure that a back-up of all relevant data of the drive has been made (cf. -
Page 64: Selecting The Download Dialog
Apply Help The user group is changed by hitting ”OK” as soon as the relevant pass- word has been entered. You may obtain the password on request from Bosch Automationstech- nik, Erbach: D Tel.: +49 (0)6062-78-0 D Email: AT-Support-Drives@bosch.com 1070 066 028-101 (01.05) GB... -
Page 65: Selecting File To Be Downloaded
Firmware Update 7–3 2. Select the menu sequence: EXTRAS " FIRMWARE DOWNLOAD " SERVODYN-D (ASM) Transmission speed to the drive. File Click this command button to select a file for download. In the event of transmission problems: D Select the lower next baudrate D Use the shortest possible transmission cable (RS-232) D If long transmission cables are used, an annular core may im- prove transmission. -
Page 66: Starting The Download
Firmware Update 7–4 Starting the download Proceed as follows: 1. Click on the ”Start” command button in the ”Firmware download” dialog. Then, the system checks whether the hex file necessary for the download is available. If this check was successful, you will be requested in an infor- mation dialog to activate the ”Bootstrap mode”... -
Page 67: Restoring The Drive Data
Firmware Update 7–5 Restoring the drive data 1. Click on the ”Bosch DSS” command button in the task bar of the operating system. The screen shows the DSS basic image. 2. Select the following menu from the DSS basic image: CONTROL "... - Page 68 Firmware Update 7–6 Notes: 1070 066 028-101 (01.05) GB...
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Page 69: Displays On The Module
Displays on the Module 8–1 Displays on the Module Status / warning displays Status Measures Axis enable external if – D 24 V at X06.3/4 (FG) present Enable internal if – D 24 V at X06.3 (FG) present D Central enable by VM present D no faults 3-digit 7-segment display Operating display:... - Page 70 Displays on the Module 8–2 Read Unit Description from A-0-1009 Utilization Current utilization of the motor, for f < f with respect to the motor torque M for f > f with respect to the motor power P Accuracy: depending on the motor, for n >...
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Page 71: Fault Messages
Displays on the Module 8–3 8.1.1 Fault messages Displays in vertical ar- Fault Measures rangement on the module Drive was switched off. Power supply unit fault D Check module cross-link Internal or external 24 V supply voltages be- D Replace module yond the admissible range Overvoltage / Driver fault D Check output stage... - Page 72 Displays on the Module 8–4 Displays in vertical ar- Fault Measures rangement on the module Drive was switched off. Error in RAM memory D Replace module EEPROM error D Replace module EEPROM cannot be read/written Real-time error D Restart module Processor error D Replace module 1070 066 028-101 (01.05) GB...
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Page 73: Index
Appendix A–1 Appendix Index Numbers 7–segment display, 8–1 Hard disk drive, 1–7 Analog outputs, 5–21 I x R compensation, 5–6 asd file IDN backup, 4–11 edit, 6–1 Initializing, DSS, 4–3 transmit to drive, 6–1 Intended use, 1–1 Interface disconnect connection cable, 4–3 Backup, 4–11 setting parameters, 4–1 Bimetallic function, 5–23... - Page 74 Appendix A–2 Release, 1–7 Reset, 4–3 RS232, 4–1 Safety instructions, 1–4 Safety markings, 1–3 Saving all data, 4–11 Selecting the language, 4–10 Series commissioning, 6–1 load files, 6–1 Setpoint, 5–10 Setpoint ramps, 5–8 Shaft output, 5–21 Slip compensation, 5–17 Spare parts, 1–6 Stalling warning, 5–18 Status displays, 8–1 Temperature sensor, 5–23...
- Page 75 A–1 Bosch-Automationstechnik Robert Bosch GmbH Robert Bosch GmbH Österreich Geschäftsbereich Geschäftsbereich Robert Bosch AG Automationstechnik Automationstechnik Geschäftsbereich Industriehydraulik Antriebs- und Steuerungstechnik Automationstechnik Postfach 30 02 40 Postfach 11 62 Hüttenbrennergasse 5 D-70442 Stuttgart D-64701 Erbach A-1030 Wien Fax (07 11) 8 11-18 57...