Bosch Rexroth Indramat ECODRIVE DKC02.1 Series Technical manual

ECODRIVE
DKC02.1 Drive Controller
DOK-ECODRV-DKC02.1****-PRJ2-EN-P
Project Planning Manual
mannesmann
Rexroth
engineering
Indramat
267473
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About this documentation ECODRIVE DKC02.1 Drive Controller
DOK-ECODRV-DKC02.1****-PRJ2-EN-P
ECODRIVE DKC02.1 Drive Controller
Project Planning Manual
DOK-ECODRV-DKC02.1****-PRJ2-EN-P
• 209-0069-4388-02
Document identification of
previous editions Status Comments
209-0069-4388-00 DE/10.95
DOK-ECODRV-DKC02.1****-PRJ1-EN-P
DOK-ECODRV-DKC02.1****-PRJ2-EN-P
Oct. 95
Oct. 96
Feb. 98
1st edition
new edition
new edition
INDRAMAT GmbH, 1995
The reproduction and transmission of this document, the use and com-
munication of its content to third parties without the expressed consent of
INDRAMAT GmbH are forbidden. Violators are liable for the payment of
damages. All rights are reserved in the event a patent is granted or a util-
ity model is registered (DIN 34-1).
INDRAMAT GmbH •Bgm.-Dr.-Nebel-Str. 2 •D-97816 Lohr a. Main
Telephone [phone] •Telex 689421 •Fax [phone]
Dept. ENA (VS, HE)
The contents of this documentation and the availability of the product are
subject to change.
Title
Type of documentation
Document type
Internal file reference
Editing sequence
Copyright
Publisher
Validity
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ECODRIVE DKC02.1 Drive Controller About this documentation
DOK-ECODRV-DKC02.1****-PRJ2-EN-P
It supplies information on:
• planning the mechanical control cabinet
• planning the electrical system in the control cabinet
• logistic handling of the equipment
• preparing the resources for start-up
"ECODRIVE Servo drives DKC with MKD"
- Selection Lists -
DOK-ECODRV-DKC+MKD****-AUS1-EN-P
for selecting the motor/controller combination.
"MKD Digital AC Motors"
- Project Planning Manual -
DOK-MOTOR*-MKD********-PRJ2-EN-P
for a detailed description of the servomotors and for the selection of the
required cable.
"ECODRIVE DKC02.1 Drive Controller"
- Function Description -
DOK-ECODRV-SSE-02VRS**-FKB1-EN-P
for testing and selecting the functions.
"EMC in Drive and Control Systems"
- Project Planning Manual -
209-0049-4305-02 DOK-GENERL-EMV********-PRJ1-EN-P/04.96
for the EMC-compliant planning and installation of the drive system
(EMC= Electromagnetic Compatibility).
“Fiber Optic Cable - Handling”
- Applications -
209-0090-4101-05 DE/10.94
for planning the fiber optic transmission links and selecting the fiber optic
cables and FSMA plug-in connector.
What is this document for?
Supplementary documentation
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About this documentation ECODRIVE DKC02.1 Drive Controller
DOK-ECODRV-DKC02.1****-PRJ2-EN-P
Notes
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ECODRIVE DKC02.1 Drive Controller Table of contents I
DOK-ECODRV-DKC02.1****-PRJ2-EN-P
Table of contents
1 Introduction to the System 1-1
1.1 Application features..............................................................................................................................1-1
1.2 Overview of the functions.....................................................................................................................1-1
2 Safety instructions for electrical drives 2-1
2.1 General ................................................................................................................................................2-1
2.2 Protection against contact with electrical parts....................................................................................2-2
2.3 Protection against shocks caused by safety extra-low voltage (SELV).........................................2-3
2.4 Protection against dangerous movements...........................................................................................2-4
2.5 Protection against magnetic and electromagnetic fields during operation and assembly ...................2-6
2.6 Protection during handling and assembly............................................................................................2-7
2.7 Safe battery usage...............................................................................................................................2-7
3 Selecting the components 3-1
3.1 Overview of the required components.................................................................................................3-1
3.2 Selection procedure.............................................................................................................................3-2
3.3 Compiling the required data.................................................................................................................3-3
4 ECODRIVE DKC drive controllers 4-1
4.1 Hardware..............................................................................................................................................4-1
Dimensional data and installation dimensions..............................................................................4-1
Technical data...............................................................................................................................4-2
Type code and rating plate............................................................................................................4-5
4.2 Firmware..............................................................................................................................................4-6
4.3 An overview of the electrical connections............................................................................................4-7
Front view with supply terminals and overall connection diagram................................................4-7
4.4 Electrical connections..........................................................................................................................4-9
Serial interface X1.........................................................................................................................4-9
X2 external measuring system......................................................................................................4-9
X3 zero switch, sensor, travel limit switch, diagnostic outputs....................................................4-10
X4 24V control voltage supply, E-stop (emergency stop), stand-by operation............................4-11
X5 connection for motor feedback ..............................................................................................4-13
X6 motor temperature, motor holding brake, 24V supply for the motor holding brake ...............4-13
X7 motor power connection ........................................................................................................4-13
X8 power connection...................................................................................................................4-14
X9 DC bus connection ................................................................................................................4-14
X10/X11 SERCOS interface connection.....................................................................................4-14
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II Table of contents ECODRIVE DKC02.1 Drive Controller
DOK-ECODRV-DKC02.1****-PRJ2-EN-P
4.5 Switches.............................................................................................................................................4-15
Switches S2, S3..........................................................................................................................4-15
Switch S4 ....................................................................................................................................4-15
5 BZM auxiliary bleeder module 5-1
5.1 Dimensioning the components relevant for regeneration ....................................................................5-1
5.2 Dimensional data and installation dimensions.....................................................................................5-5
5.3 Technical data......................................................................................................................................5-6
5.4 Front view.............................................................................................................................................5-6
5.5 Electrical connection............................................................................................................................5-7
5.6 Type code and rating plate...................................................................................................................5-7
6 CZM auxiliary capacitance module 6-1
6.1 Dimensioning .......................................................................................................................................6-1
6.2 Dimensional data and installation dimensions.....................................................................................6-3
6.3 Front view.............................................................................................................................................6-4
6.4 Electrical connection............................................................................................................................6-4
6.5 Type code and rating plate...................................................................................................................6-5
7 DC24V power supplies NTM 7-1
7.1 Application recommendations..............................................................................................................7-1
7.2 Technical data......................................................................................................................................7-1
7.3 Dimensional data and installation dimensions.....................................................................................7-2
7.4 Front views...........................................................................................................................................7-2
7.5 Electrical connection............................................................................................................................7-3
7.6 Type code ............................................................................................................................................7-4
8 Line filter NFD/ NFE 8-1
8.1 Selection ..............................................................................................................................................8-1
Technical data for line filters .........................................................................................................8-1
Ambient conditions for line filters ..................................................................................................8-1
8.2 Dimensional data and installation dimensions.....................................................................................8-2
8.3 Electrical connection............................................................................................................................8-3
8.4 Line filters for DC24V NTM power supplies.........................................................................................8-4
8.5 Type code ............................................................................................................................................8-4
9 DST / DLT transformers 9-1
9.1 Selection ..............................................................................................................................................9-1
9.2 Autotransformers for DKC**.*-040-7-FW.............................................................................................9-1
9.3 Electrical connection of the DKC via transformer ................................................................................9-4
9.4 Type code ............................................................................................................................................9-4
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ECODRIVE DKC02.1 Drive Controller Table of contents III
DOK-ECODRV-DKC02.1****-PRJ2-EN-P
10 Planning the control cabinet 10-1
10.1 Notes on installing the control cabinet.............................................................................................10-1
Power dissipation........................................................................................................................10-1
10.2 Using heat-exchange units in the control cabinets ..........................................................................10-2
10.3 Interference suppression measures and EMC ................................................................................10-4
11 Power connection 11-1
11.1 Direct power connection...................................................................................................................11-1
11.2 Line contactor/fuse protector ...........................................................................................................11-2
Calculating the phase current at the power connection..............................................................11-2
Selecting the fuse protector Q1 and line contactor K1................................................................11-3
11.3 Control circuit to the power connection............................................................................................11-4
11.4 Reaction of the drive to malfunctions...............................................................................................11-6
Power failure ............................................................................................................................... 11-6
24 V control voltage failure for the DKC......................................................................................11-6
Fatal errors..................................................................................................................................11-7
Other errors.................................................................................................................................11-7
11.5 Protection against indirect contact...................................................................................................11-7
12 Preparing for Startup 12-1
Required equipment....................................................................................................................12-1
13 Condition of the drive components on delivery 13-1
Packaging ...................................................................................................................................13-1
Accompanying documents..........................................................................................................13-1
14 Index 14-1
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IV Table of contents ECODRIVE DKC02.1 Drive Controller
DOK-ECODRV-DKC02.1****-PRJ2-EN-P
Notes
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ECODRIVE DKC02.1 Drive Controller Introduction to the system 1-1
DOK-ECODRV-DKC02.1****-PRJ2-EN-P
1 Introduction to the system
1.1 Application features
The drive system with the ECODRIVE drive controllers is the most cost-
effective solution offering the highest functionality for almost any field of
application in which translatory or rotary motions are to be automated.
Outstanding performance data, an extensive range of functions as well as
an excellent price-to-performance ratio represent the salient features of
this drive system.
Product features in terms of the technical applications are:
• universal implementation
• lower total costs
• digital drive concept
• highly dynamic operation
• cost-effective direct connection to the power connection
• software travel limit switch
• absolute or incremental position detection
• integrated holding brake control
• increased operating safety
• adjustable error response
• automatic parameter matching
• easy startup operation
1.2 Overview of the functions
ECODRIVE is a digital, intelligent drive family for AC servodrives.
ECODRIVE AC servodrives are microprocessor-controlled, brushless
three-phase drives with servocontroller characteristics.
The drives are monitored, parameterized, diagnosed, and controlled en-
tirely digitally by means of a signal processor which accurately measures
the rotor position in the entire speed range.
ECODRIVE consists of:
• a DKC drive controller
• a MKD AC motor
ECODRIVE
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1-2 Introduction to the system ECODRIVE DKC02.1 Drive Controller
DOK-ECODRV-DKC02.1****-PRJ2-EN-P
DKC02.1 drive controller with SERCOS
interface AC MKD
servo motor
Control unit
Linear scale
FP5101F5.fh5
M
3~
~
~
SERCOS
interface SERCOS interface
Drive processor
Fine interpolation
Position control
Speed control
Torque control
Field-oriented
stator current
control
Parameters
Diagnosis
Operating data
High-resolution
positioning interface
High-resolution
positioning interface
Fig. 1-1: Interworking of the control, digital drive controller, and AC motor
The drive controller DKC02.1 features the SEROS interface as control
interface.
The SERCOS interface is a serial real-time communication system. The
control and drives are interconnected in a ring via a fiber optic cable. Data
is exchanged serially between the control and drives over this fiber optic
cable.
This drive interface has been the international standard for CNC ma-
chines since 1995.
The SERCOS interface offers users the following features which are im-
portant for data transmission between bus systems.
• The ring structure reduces the wiring to a minimum. Fiber optic cables
ensure the highest possible noise immunity while at the same time of-
fer high data transfer rates.
• All exchangable data, parameters and commands used in operation
have been standardized.
• The SERCOS interface makes it possible to conduct an extensive di-
agnosis and parameterize the drives via terminals from SERCOS in-
terface compatible controls. This reduces startup times and downtimes
considerably.
• Drives and CNC controls from various manufacturers can be used to-
gether in any combination.
SERCOS interface
Features of the SERCOS
interface
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ECODRIVE DKC02.1 Drive Controller Introduction to the system 1-3
DOK-ECODRV-DKC02.1****-PRJ2-EN-P
The drive controller comprises:
• the SERCOS interface as a control interface
• the operating modes: position control, position control and interpolation
in the drive (target position is preset), speed control, and torque control
• a drive-internal referencing procedure is available for creating a refer-
ence dimension.
• travel limit switch inputs and axis limit values which can be parame-
terized are available for limiting the travel range.
• two measuring probe inputs are available for measuring.
• mechanical translatory elements such as gear ratios or feed constants
are adapted in the drive.
• all position, speed, and acceleration data can be weighted independ-
ently of the axis kinematics.
• connection for analyzing data from an external encoder (voltage sig-
nals 1Vss) if a measuring system must be directly connected to the
machine element. the indirect position is always present via the motor
feedback.
• connection for three-phase lines 3 x AC 380 ...480 V, 50...60 Hz
Minimum SERCOS cycle time: 2 ms
Data rate: 2 or 4 Mbit/s
Internal position control cycle time 500 µs
Resolution of the signal period
of an external measuring system: 2048-fold
Maximum frequency for 1Vss signals
of the external measuring system: 200 kHz
For technical data, refer to page 4-2.
The digital AC motor MKD is a permanent electromagnetic excitation
motor with electronic commutation.
The MKD motors are equipped with measuring systems (motor feedback)
used for indirect actual position detection.
The MKD motors can be optionally equipped with absolute encoder
measuring systems.
A data storage is present in the motor feedback that contains the motor
parameters and thus ensures adjustment to the motor drive controller
without the risk of damaging the motor. It also makes startup operation
quick and easy.
For detailed information on the motor, please refer to the project planning
manual "MKD Digital AC Motors".
Drive controller
Drive data
Motor
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1-4 Introduction to the system ECODRIVE DKC02.1 Drive Controller
DOK-ECODRV-DKC02.1****-PRJ2-EN-P
Notes
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ECODRIVE DKC02.1 Drive Controller Safety instructions for electrical drives 2-1
DOK-ECODRV-DKC02.1****-PRJ2-EN-P
2 Safety instructions for electrical drives
Please read the following instructions carefully before initial startup.
These safety instructions must be observed at all times.
If the product is transferred to a third-party, the safety instructions must be
included.
WARNING
Improper use of this equipment and non-compliance
with the safety instructions provided can result in
damage, personal injury or, in extreme cases, death.
2.1 General
INDRAMAT GmbH is not liable for any damages resulting from failure
to observe the safety instructions in this document.
• Documentation in the relevant national language should be obtained
before initial startup if the language in this documentation is not per-
fectly understood.
• Proper transport, correct storage, assembly, and installation as well as
care in operation and maintenance are prerequisites for optimum and
safe operation of this equipment.
• Qualified personnel:
Only qualified personnel should be permitted to operate this equipment
or work in its immediate vicinity. Personnel is considered qualified if it
has sufficient knowledge of the assembly, installation, and operation of
the product as well as all warnings and precautionary measures in this
documentation.
Furthermore, personnel should be trained, instructed or authorized to
switch electrical circuits on and off and to ground and mark them in
accordance with the requirements of safety engineering. Personnel
should possess adequate safety equipment and be trained in first aid.
• Use only replacement parts approved by the manufacturer.
• All safety regulations and requirements for the specific application
must be followed.
• The equipment is designed to be installed in machines for commercial
use.
• Startup is only permitted once it is sure that the machine in which the
products are installed complies with the requirements of the national
safety regulations and safety specifications of the application.
European countries: EC Directive 89/392/EEC (Machine Guideline)
• Operation is only permitted if the national EMC regulations for the spe-
cific application have been met.
European countries: EC Directive 89/336/EEC (EMC Guideline)
The instructions for installation in accordance with EMC requirements
can be found in the document "EMC Drive and Control Systems."
The responsibility for adherence to the limiting values required by na-
tional regulations lies with the manufacturer of the equipment or ma-
chine.
• Technical specifications as well as the connection and installation re-
quirements can be found in the product documentation and must be
observed under all circumstances.
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2-2 Safety instructions for electrical drives ECODRIVE DKC02.1 Drive Controller
DOK-ECODRV-DKC02.1****-PRJ2-EN-P
2.2 Protection against contact with electrical parts
Note: Only relevant for devices and drive components with voltages
exceeding 50 volts.
Coming into contact with components carrying voltages greater than 50
volts can be dangerous. Certain parts are under dangerous voltage when
operating electrical devices.
DANGER
High Voltage!
Danger to life or risk of bodily injury!
⇒ Follow general construction and safety regulations
when working on electrical installations.
⇒ Before switching on power, be sure that the ground
wire is permanently connected to all electrical units
according to the connection diagram.
⇒ At no time may electrical equipment be operated if the
ground wire is not permanently connected to the
proper terminals, even for brief measurements or
tests.
⇒ Disconnect the equipment from the power supply line
or the voltage source before beginning work. Secure
equipment from reclosure.
⇒ Wait 5 minutes after switching off power to allow ca-
pacitors to discharge before using the equipment.
Measure the voltage of the capacitors before begin-
ning work in order to eliminate dangers arising from
touching components.
⇒ Never touch the electrical connection points of a com-
ponent while the power is turned on.
⇒ Cover live parts properly before switching the equip-
ment on so they cannot be touched. Covers provided
with the equipment must be installed before operating
the equipment to prevent contact with live parts. The
equipment may only be operated with the covers de-
signed for shock-hazard protection.
⇒ A GFCI protective device (ground fault circuit inter-
rupter) cannot be used for AC drives! Protection
against indirect contact must be ensured by other
means, for example, by using an overcurrent protec-
tion device in accordance with relevant standards.
European countries: in accordance with EN 50178/
1994, section 5.3.2.3
⇒ For installation equipment protection against indirect
contact must be ensured using an external housing,
such as a control cabinet. European countries: in ac-
cordance with EN 50178/1994, section 5.3.2.3
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ECODRIVE DKC02.1 Drive Controller Safety instructions for electrical drives 2-3
DOK-ECODRV-DKC02.1****-PRJ2-EN-P
WARNING
High discharge current!
Danger to life or risk of bodily injury!
⇒ All units and the motors must first be connected to a
grounding point with the ground wire or must be
grounded themselves before switching on power.
⇒ The discharge current is greater than 3.5 mA.
A permanent connection to the power supply system
is therefore required for all units. European countries
(EN 50178/1994, section 5.3.2.3).
⇒ Before startup operation always connect the protec-
tive conductor or the ground conductor. Otherwise the
housing may harbor high voltages.
2.3 Protection against shocks caused by safety extra-low
voltage (SELV)
All connectors and terminals on INDRAMAT products with voltages from
5 to 50 volts are safety extra-low voltages offering a shockproof design to
meet the following standards:
• international: IEC 364-4-411.1.5
• European countries in the EC: EN 50178/1994, section 5.2.8.1
WARNING
High electrical voltages due to incorrect connec-
tions!
Danger to life or risk of bodily injury!
⇒ Only equipment and lines carrying protective extra low
voltage (PELV) may be connected to connectors and
terminals with voltages ranging from 0 to 50 volts.
⇒ Connect only voltages and circuits safely isolated from
dangerous voltages. Isolation can be achieved, for
example, by using safe isolation transformers, opto-
couplers or power supply independent battery opera-
tion.
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2-4 Safety instructions for electrical drives ECODRIVE DKC02.1 Drive Controller
DOK-ECODRV-DKC02.1****-PRJ2-EN-P
2.4 Protection against dangerous movements
Dangerous movements can be caused if the connected motors are not
controlled correctly.
There are various causes of dangerous movements:
• faulty wiring or cable connections
• operating the components improperly
• defective measured value transmitters and primary detectors
• defective components
• errors in the software
These errors can occur just after the equipment has been switched on or
after an indefinite period of time.
The monitors in the drive components virtually exclude failure in the con-
nected drives. However, personnel safety requires that additional meas-
ures be taken to ensure correct operation. Faulty drive motions which are
influenced by the type of control and the operating status cannot be en-
tirely excluded until the installed monitors take effect.
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ECODRIVE DKC02.1 Drive Controller Safety instructions for electrical drives 2-5
DOK-ECODRV-DKC02.1****-PRJ2-EN-P
DANGER
Dangerous movements!
Danger may result in equipment damage, personal injury
or death!
⇒ Personal safety must be ensured by higher-level,
monitoring at the installation or precautionary meas-
ures for the reasons listed above. These are provided
by the plant manufacturer according to the specific
conditions of the plant based on a danger and mal-
function analysis. The safety regulations in effect for
the plant are included herein.
Avoiding accidents:
⇒ Stay away from the machine’s movement area. Pos-
sible measures to be taken to prevent access by un-
authorized persons:
- protective fences
- protective railings
- protective coverings
- light barrier
⇒ Fences and coverings should be strong enough to
withstand the maximum possible momentum.
⇒ Mount the emergency stop (E-stop) switch at an easily
accessible place in the immediate vicinity. Verify that
the E-stop switch works before starting operation.
⇒ Isolate the drive power connection by means of an E-
stop circuit or use a starting lock-out to prevent unin-
tentional startup.
⇒ Make sure that the drives have been shut down be-
fore accessing or entering the danger zone.
⇒ Disable electrical power to the equipment using a
master switch and secure against reclosure during:
- maintenance and repair work
- equipment cleaning
- long downtime periods
⇒ Avoid operating high-frequency, remote control, and
radio equipment near electrical equipment and their
supply leads. If the use of such equipment cannot be
avoided, verify that the system and plant are in perfect
working order in all working situations before initial
operation. If necessary, the plant must undergo spe-
cial EMC testing.
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2-6 Safety instructions for electrical drives ECODRIVE DKC02.1 Drive Controller
DOK-ECODRV-DKC02.1****-PRJ2-EN-P
2.5 Protection against magnetic and electromagnetic fields
during operation and assembly
Magnetic and electromagnetic fields near current-carrying conductors and
permanent magnets pose a serious health hazard for persons with pace-
makers, metal implants and hearing aids.
WARNING
Health hazard for persons with pacemakers, metal
implants and hearing aids in the immediate vicinity
of electrical equipment.
⇒ Persons with pacemakers and metal implants must
not be permitted access to the following areas:
− Areas in which electrical equipment and parts are
mounted, operated or put into operation.
− Areas in which motor parts with permanent mag-
nets are stored, repaired or mounted.
⇒ If it becomes necessary for a person with a pace-
maker to enter such an area, this must be approved
by a physician beforehand.
Implanted pacemakers or those to be implanted have
a varying degrees of resistance to interference, mak-
ing it impossible to establish any general guidelines.
⇒ Persons with metal implants or metal splitters as well
as hearing aids should consult a physician before en-
tering such areas since they represent a health haz-
ard.
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ECODRIVE DKC02.1 Drive Controller Safety instructions for electrical drives 2-7
DOK-ECODRV-DKC02.1****-PRJ2-EN-P
2.6 Protection during handling and assembly
Handling or assembling drive components improperly may lead to per-
sonal injury.
CAUTION
Risk of injury due to improper handling!
Bodily injury may be caused by crushing, shearing, cut-
ting, and pounding forces.
⇒ Observe general construction and safety regulations
when working on electrical installations.
⇒ Use suitable assembly and transport equipment.
⇒ Take precautions to prevent pinching and crushing.
⇒ Use only suitable tools. Use special tools as pre-
scribed.
⇒ Employ lifting devices and tools according to the
manufacturers’ instructions.
⇒ If necessary, use suitable protective equipment (for
example goggles, safety shoes, protective gloves).
⇒ Do not stand under suspended loads.
⇒ Remove any leaking liquids on the floor immediately
to prevent slipping.
2.7 Safe battery usage
Batteries consist of reactive chemicals contained in a solid case. Im-
proper use can therefore lead to injuries or equipment damage.
CAUTION
Risk of injury due to improper handling!
⇒ Do not attempt to reactivate empty batteries by heat-
ing them or by any other means (danger of explosion
or corrosion).
⇒ Do not recharge batteries because they may leak or
explode.
⇒ Do not dispose of batteries by throwing them into a
fire.
⇒ Do not attempt to disassemble batteries.
⇒ Do not damage the electrical components installed in
the equipment.
Note: Environmental protection and disposal! The batteries con-
tained in the product are considered hazardous material for
land, sea, and air transport according to the legal regulations
(danger of explosion). Dispose used batteries separately from
other waste. Observe the national regulations in the country of
installation.
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2-8 Safety instructions for electrical drives ECODRIVE DKC02.1 Drive Controller
DOK-ECODRV-DKC02.1****-PRJ2-EN-P
Notes
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