Mannesmann Rexroth Indramat DDC Series Instructions for use

DDC and MDD
Digital Intelligent AC Servo Drives with Single
Axis Positioning Module
DOK-CONTRL-DDC+MDD+DLC-ANW1-EN-P
Application Manual
mannesmann
Rexroth
engineering
Indramat
271433

About this documentation
• DOK-CONTRL-DDC+MDD+DLC-ANW1-EN-E1,44 • 01.97
2
Title
DDC and MDD
Digital Intelligent AC Servo Drives with Single Axis Positioning Module
Type of documentation
Applications Manual
Document code
DOK-CONTRL-DDC+MDD+DLC-ANW1-EN-E1,44
Internal file reference
• Mappe13
• DDC01-AN.pdf
• 209-0069-4393-00
Reference
This electronic document is based on the hardcopy document with docu-
ment desig.: DOK-CONTRL-DDC+MDD+DLC-ANW1-EN-P • 08.96
The purpose of this
documentation
This applications manual is intended
• to supply information on the components of digital AC servo drives
• to offer mounting guidelines
• to assist when checking electrical connections of digital AC servo drives
with single-axis positioning modules
• to assist in determining drive and controller parameters for setup operati-
ons
• to offer commissioning support through to setup operations
• to support the application of DLC functions
• to assist in locating and clearing faults
Editing sequence
Copyright
© INDRAMAT GmbH, 1996
Copying this document, and giving it to others and the use or communica-
tion of the contents thereof without express authority, are forbidden. Offen-
ders are liable for the payment of damages. All rights are reserved in the
event of the grant of a patent or the registration of a utility model or design
(DIN 34-1).
The electronic documentation (E-doc) may be copied as often as needed if
such are to be used by the consumer for the purpose intended.
Publisher
INDRAMAT GmbH • Bgm.-Dr.-Nebel-Straße 2 • D-97816 Lohr Telefon 0 93
52 / 40-0 • Tx 689421 • Fax 0 93 52 / 40-48 85 Dept ENA (DE, FS)
Validity
All rights are reserved with respect to the content of this documentation and
the availability of the product.
Doc. designtion of previous editions Status Comment
DOK-CONTRL-DDC+MDD+DLC-ANW1-EN-P
DOK-CONTRL-DDC+MDD+DLC-ANW1-EN-E1,44
Aug. 96 1st edition
1st edition E-Doc

Table of Contents
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Table of Contents
Page
1. Introducing the System 7
1.1. Types of Digital Drives .....................................................................8
2. Components of Digital AC Servo drives with
a DLC Single-Axis Positioning Module 10
2.1. Basic Unit .......................................................................................12
2.2. DLC 1.1 Single-Axis Positioning Module .......................................12
2.3. Software Module ............................................................................13
2.4. Auxiliary Plug-In Cards ..................................................................14
2.5. Configuration Rating Plate .............................................................14
2.6. Digital AC Servo Motors .................................................................16
3. Mounting and Assembly 18
3.1. Mounting the drive .........................................................................18
3.2. Power connections of the DDC ......................................................19
3.3. DDC - dimensional data .................................................................20
3.4. Frontal view - DDC 1 ......................................................................21
3.5. Coupling the Feed Motor to the Machine .......................................22
4. Electrical Connections 23
4.1. Terminal diagram - DDC 1.1 ..........................................................25
4.2. Controlling the Mains Contactor .....................................................26
4.3. DLC 1.1 Single-Axis Positioning Module .......................................28
4.4. DEA 4.1, DEA 5.1 and DEA 6.1 Input/Output Interfaces ...............30
4.5. Positioning Interface for DEF 1.1 and DEF 2.1
Square-Wave Signals ....................................................................32
4.6. INTERBUS S Connection ..............................................................34
5. Start-Up Aids 36
5.1. Minimum Equipment ......................................................................36
5.2. Recommended Equipment for Service and Start-Up of the
Drive Controllers ............................................................................36
5.3. Recommended Equipment for Service and Start-Ups of
DLC Single-Axis Positioning Modules ............................................37
5.4. Connecting the Start-Up Aids ........................................................38

Table of Contents
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6. Parameter Input 39
6.1. Parameter Input Aids .....................................................................39
6.2. Using the CTA to Input Parameters ...............................................40
6.3. Parameter Input Preparations ........................................................41
6.4. Inputting Parameters ......................................................................42
6.5. Explanatory Notes on Several Important DLC Parameters ...........44
6.6. Example 1 - Linear Axis with Absolute Position Measurement
(in motors with integrated multiturn encoder) .................................49
6.7. Example 2 - Linear Axis with Incremental Position Measurement
(e.g., motors with digital DSF servo feedback) .............................51
6.8. Example 3 - Linear Axis with Direct Position Measurement ..........53
6.9. Example 4 - Rotary Table with Incremental Position Measurement 55
6.10. Parameter List for the Machine Documents ...................................57
6.11. Parameter Input Limits ...................................................................59
7. Commissioning 60
7.1. Powering Up ..................................................................................60
7.2. Check the Traversing Direction (Working Direction) of the
Feed Axis .......................................................................................62
7.3. Establishing a Reference Dimension .............................................62
7.4. Determining Short-Term Torque - Setting the Overload Factor .....62
7.5. Error Reaction ................................................................................64
7.6. Check Motor Holding Brake ...........................................................67
7.7. Parametrizing the Speed Controller ...............................................68
7.8. Check Drive Load ..........................................................................70
7.9. Securing Data ................................................................................71
8. Functions of the DLC Single-Axis Positioning Module 72
8.1. Homing a Linear Axis with Indirect, Relative Position Detection
(e.g., DSF digital servo feedback) ..................................................72
8.2. Referencing a Linear Axis with Direct Position Detection
(e.g., Linear Scale) ........................................................................74
8.3. Establishing the Dimensional Reference of a Linear Axis with
Multiturn Encoder (MTG) ...............................................................77
8.4. Setting Position Offset (Zero Point Offset) .....................................80
8.5. Positioning Against a Dead Stop ...................................................81
8.6. Interrupt Vector (Jump on Event) ...................................................83
8.7. Speed Override ..............................................................................84
8.8. Setup Mode ....................................................................................86

Table of Contents
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8.9. Automatic Mode .............................................................................87
9. Diagnostics and Fault Clearance 90
9.1. Operating Status Display of the Drive Controller ...........................91
9.2. Fault Displays of the Drive Controller ............................................92
9.3. Diagnostics Possibilities with a CTA Programming and
Display Unit ..................................................................................101
9.4. Error Displays of a CTA Programming and Display Unit .............102
9.5. Replacing the Battery ...................................................................104
9.6. Replacing the Forward Feed Motor .............................................105
9.7. Fault Report .................................................................................108
10. Index 110

Table of Contents
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1. Introducing the System
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1. Introducing the System
Digital AC Drives
Digital AC drives are microprocessor controlled, brushless, three-phase cur-
rent drives with high dynamics and precise servo drive features.
The entire scope of
• drive control,
• monitoring,
• parametrization and
• diagnosis
are performed digitally by a signal processor based on high-resolution mea-
surement of the rotor position across the full speed range.
Digital AC drives with
with a DLC single-axis
positioning module
By equipping the drive with the DLC 1.1 single-axis positioning module
means that the drives can be operated as digital intelligent single-axis posi-
tioning controllers.
Fig 1.1: Digital AC servo drives and single-axis positioning modules DLC 1.1
M
3~
~
~
Digital intelligent drive controller
with single-axis positioning module digital
AC servo motor
higher-level
system
Posi-
tioning
module
DLC
max. 4 plug-in modules
Parameters
Diagnoses
Oper. data
RS 232
PLC
Field
bus
system
or
I / O
module
e.g.,
DEA
X
-
Kv
+
W
Xdω
RS 232
Kv = loop gain factor
W = reference input variable
X = controlled variable
Xd= W-X
ω= speed command value
drive computer
speed
control
field oriented
stator current
control
high-resolution
positioning interface
FPpos
RS 232
keyboard
RS 485
keyboard
user
program

1. Introducing the System
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The DLC 1.1 single-axis positioning module offers the following features:
• A user-oriented programming language.
• Easy input of up to 3,000 program blocks, e.g., position and speed ent-
ries, input queries, output settings and markers for control and motion
sequences.
• A current motion sequence can be monitored while the next program
block is simultaneously being executed.
• The drive can be matched to both the mechanical and electrical conditi-
ons of the machine by means of parameters.
• The input parameter blocks are monitored for errors and maintaining the
limit values of the system which have been entered.
• It is possible to parametrize/program with, e.g., a CTA programming key-
pad, an IDA decade switch unit, a higher-ranking PC, an SOT pro-
gramming terminal or a higher-ranking PLC.
For more detailed information about single-axis positioning modules, see
doc. no. 109-0852-4102 „DLC1-A, Single-Axis Positioning Module for Drive
Controllers, Programming Guidelines“.
1.1. Types of Digital Drives
Drive controllers for digital AC servo drives are available in the following hou-
sing designs:
• modular housing
• compact housing (protection categories IP10 and IP65)
Drive controllers for
modular housing
A drive package is made up of one supply unit and several drive controllers.
This type of construction makes it possible to combine AC servo drives and
AC main spindle drives with various outputs to drive packages that receive
their power from a shared supply unit.Supply modules are available that can
be directly connected to three-phase mains of 3 x AC 380 to 460 V, 50 to 60
Hz. INDRAMAT makes the necessary documentation available.
Drive controllers for
compact housing
Fig 1.2: Drive controllers in compact housing
Drive controllers in compact housing combine a mains rectifier and a drive
controller in one unit.
DKS01.1 drive with
protection category IP 10
FAgeräte
DDC01.1 drive with
protection category IP 65
H1
X4
X2
X5
X6
X9
X8
S1
X7 X3
SYSTEMKONFIGURATION
SYSTEMKONFIGURATION

1. Introducing the System
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Mounting directly to the
forward feed unit
INDRAMAT drive controllers with integral DLC single-axis positioning
moudle have been especially designed for the requirements of complex
finishing facilities, e.g., transfer systems.
The drive controllers with protection category IP 65 can be directly installed
to the forward forward feed unit.This means that motor power and feedback
cables which are long and conducted through the entire facility thus making
them susceptible to excessive faults are no longer needed.
The forward forward feed unit can be operated as a standalone unit. It can
also be tested independently of the machinery.
Fig 1.3: Mounting directly to the forward forward feed unit
PZtransfer
A1
A2 A1
A2
A1
A2

2. Components of Digital AC Servo drives with a DLC Single-Axis Positioning
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2. Components of Digital AC Servo drives
with a DLC Single-Axis Positioning
Module
Components of digital
AC servo drives with
DDC 1.1 and DLC
single-axis positioning
module
Fig 2.1: Digital AC drive with DDC drive controller
Components of the
drive controller
The implementation of drive controllers for the most varying of tasks means
that it must be possible to functionally adjust the respective drive controller.
This is achieved by equipping the basic unit with different auxiliary plug-in
cards and a matching software module. The thus equipped basic unit is
designated a "configured drive controller". This configured drive controller
together with a digital MDD AC servo motor creates a "system configura-
tion".
Configured drive
controller
The configured DDC drive is supplied by INDRAMAT as a fully equipped
unit.
A1
A2
PZantrDDC
Configured
DDC 1.1
drive
Motor feedback
cable
Motor
power cable
AC servo
motor MDD
Plug-in module
Software module
Power supply
Configuration
rating plate
Interface to
machine controller

2. Components of Digital AC Servo drives with a DLC Single-Axis Positioning
• DOK-CONTRL-DDC+MDD+DLC-ANW1-EN-E1,44 • 01.97
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A configured drive controller is made up the following components:
• the basic unit
• a DLC single-axis positioning module
• the software module
• an optional auxiliary plug-in module
• the configuration rating plate
Fig 2.2: DDC1 configured drive controller
A1
A2
Drive controller, basic unit
Software module DSM
Auxiliary plug-
in module PZmodDDC
Configuration
rating plate
DLC single-axis
positioning module
Slot U5
Slot U4
Slot U3
Slot U2
Slot U1
DSM
DLC

2. Components of Digital AC Servo drives with a DLC Single-Axis Positioning
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2.1. Basic Unit
The basic unit is made up of a DC bus rectifier, the bleeder resistor for taking
up the energy generated during braking and a mains section for the control
voltages. Plug-in modules are inserted into slots U1 through U5 to accomo-
date specific requirements.
Fig 2.3: Block diagram of a DDC 1 basic unit
2.2. DLC 1.1 Single-Axis Positioning Module
The single-axis positioning module expands the drive controller to create a
standalone single-axis positioning controller.This controller can be program-
med with up to 3,000 program blocks. Each program block specifies one
motion sequence or a specific state of the inputs that require monitoring or
of the outputs that need to be set.
Fig 2.4: A front view of a DLC
DCDC
A
B
C
K1
Motor feedback
µP
Bb1 ready to switch power on
~=
DC bus
short circuit
Bleeder
Motor
connection
FPAuflei
88
P
ower supply
connection
FADLC
Type
DLC 1.1
X 31 X 30
9 pin D-subminiature
plug-in connector male
to connect an
RS 232/RS 485
interface
34-pin plug-in connector
female to connect a programming
and display unit, e.g., CTA
Looking onto front panel

2. Components of Digital AC Servo drives with a DLC Single-Axis Positioning
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2.3. Software Module
Parameters, stored in the software module, are implemented for matching
the drive controller to the motor and the mechanical system of the machine.
Fig 2.5: A DSM 2. software module
Advantages when
replacing equipment
Operating software and drive parameters are stored on the DSM software
module. This means that in the event that a unit must be replaced it is not
necessary to re-tune the replacement. Simply remove the software module
from the faulty drive and install it on the new replacement unit.This configu-
res the drive for motor and machine.
Duplication
Software modules can be duplicated for additional identical machines or to
back up the parameters.This is done over a serial interface.
Standard software
module
The drive-specific parameters determined by INDRAMAT are stored in the
feedback of the MDD motors and are activated during commissioning as
needed.
The user-specific parameters are set on-site on the machine to the
machine-dependent values.
Compatibility of
sotware modules
The latest engineering revision level (software module update) used for ope-
rating the drive will be shipped without a change in the order numbers, i.e.,
the type codes becoming necessary. New software modules are compatible
to those already shipped.
PZDSM
DSM 2.1-C11-01RS
DSM 2.1
SN . . . . . . . . . .- . . . A00S02
Software version Serial number
Abbreviation
Type of software module
Barcode
It is the responsibility of the customer to document and manage the
user-specific parameter values.

2. Components of Digital AC Servo drives with a DLC Single-Axis Positioning
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2.4. Auxiliary Plug-In Cards
The following plug-in cards have been summarized under the heading of
"Auxiliary Plug-In Cards".
Input/output interfaces
Type: DEA 4.1, DEA 5.1 and DEA 6.1
These plug-in modules each have 15 inputs and 16 outputs with which the
drive can exchange binary signals.
Different addresses are set on each card.
The DEA 4.1 has eight inputs and five outputs for functions such as E-stop
input, signalling of operating mode and fault messages. Still available are
seven inputs and eleven outputs.
Interbus S interface
module
Type: DBS 2.2
With the interbus S DBS 2.2 interface module, the drive is connected to an
interbus S data highway. The DBS 2.2 can only be used in conjunction with
the single-axis positioning module DLC 2.1 . The operating modes target
position entry and local operations are possible.In local operations, it is pos-
sible to replace the physical I/O level with the interbus S interface module.
Fig 2.6: Auxiliary plug-in cards
2.5. Configuration Rating Plate
The type designation is on the configuration rating plate:
• the configured drive controller
• the basic unit
• the software module in slot U5
• the plug-in modules in slots U1 through U4
With the use of this type designation, it is possible to determine which com-
ponents should be in which slots.
In the event of a problem, the information on the rating plate can be used to
quickly locate a replacement for the problem part or a new basic unit can be
quickly fitted. A replacement unit is obtained by inserting the specifically
required modules into the basic unit specified on the rating plate.
DEF 1.1
DLC 1.1
X 31 X 30
DBS 1.1
X38
X37
H1
H2
H3
H4
RB
BA
RC
ME
FAzumod
DEA 4.1
Type
DEA DEF DLC2.1
Type
DBS2.2
Type Type

2. Components of Digital AC Servo drives with a DLC Single-Axis Positioning
• DOK-CONTRL-DDC+MDD+DLC-ANW1-EN-E1,44 • 01.97
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Fig 2.7: An example of a configuration rating plate
Fig 2.8: DDC drive type codes
Only those configurations specified by INDRAMAT may be used.
The configuration rating plate lists those modules which can be
used with a specific drive. Prior to commissioning a drive, make
sure that the one specified on the rating plate is the one that is
actually in use in this case.
TSDDC
SYSTEMCONFIGURATION
DDC 1.1-K050A-DL01-00
DDC 1.1-K050A-A
DSM 2.1-C11-01.RS
DLC 1.1
DEA 4.1
COVER
COVER
U
1
U
2
U
3
U
4
U
5
TYS-DDC 1.1-W050A-DL01-00
Slot designation
Type of configured
drive controllers
Basic unit type
Plug-in module type
Software module type
Configuration
rating plate
type
COVER = cover, no plug-in module in slot
Product name
DDC
Series
1
Version
1
Cooling
liquid
air
control enclosure outside air (external)
Rated current
50 A
100 A
150 A
200 A
Noise emission at motor
standard
(50 A ... 200 A rated current)
reduced
(only with 50 A rated current)
Configuration designation
Example:
DDC 01. 1-K 050 B-DA01-00
= DDC
= 1
= 1
=F
=K
=050
=100
=150
=200
=A
=B
1.
2.
3.
4.
5.
6.
7. TLDDC

2. Components of Digital AC Servo drives with a DLC Single-Axis Positioning
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2.6. Digital AC Servo Motors
Fig 2.9: An MDD motor
The digital MDD AC servo motors are available in the following feedback
versions:
• motors with digital servo feedback (DSF)
• motors with digital servo feedback and multiturn encoders (DSF+MTG)
Fig 2.10: Feedback features
Digital Feedback Sensor Principle:
optical probing of code disc
Position resolution achieved 256 x 2
13
= 2 097 152 increments/revolutions
System accuracy +/- 0.5 angular minutes
Multiturn type 4 095.99 rotor revolutions
Available with MDD 065 through MDD 115
Suitable applications high demands made of control dynamics,
synchronous behavior, absolute accuracy
Side A Side B
FAMD112
feedback
Feedback data

2. Components of Digital AC Servo drives with a DLC Single-Axis Positioning
• DOK-CONTRL-DDC+MDD+DLC-ANW1-EN-E1,44 • 01.97
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MDD motor type codes
Fig 2.11:Type codes for an MDD servo motor for decoding the feedback version and execut-
ing the holding brake
The respective motor documentation can offer supplementary data on this
subject.
Rating plate
Fig 2.12: An MDD motor rating plate
Upon commissioning, check to make sure that the continuous torque of the
motor, as designated on the rating plate, is not exceeded.
1. Name
2. Motor size
3. Motor length
4. Housing type:
5. Rated speed
6. Balance class
7. Side B shaft end
8. Motor feedback
RSF
RSF + IDG
DSF
DSF + MTG
G
K
L
M
9. Centering diameter
10. Output shaft
11. Power conn., mounting orientation
12. Blocking brake
without blocking brake
with blocking brake 14.0 Nm
with blocking brake 40.0 Nm
with blocking brake 60.0 Nm
0
1
2
3
Example: MDD 112 B-N-015-N 2 L-130 G B 0
TLMDD
TSMDD
Part No.
S.No. Build Week Com.No.
Made in Germany
I.Cl.
n
PERMANENT MAGNET MOTOR
Natural Convection
INN 13.06
MdN Nm
IdN
AMdN Nm
IdN Amin-1 Km kg
m
Brake
DC 24 V +-10%
123456 44/91 234567
MDD090-123456
MDD090C-N2L-110GB0/S016
10.4 16.0
9.5 14.6
F2000
1.10
50 Nm/A
3
IP 65 Surface cooled
Nm14.0 A0.75

3. Mounting and Assembly
• DOK-CONTRL-DDC+MDD+DLC-ANW1-EN-E1,44 • 01.97 18
3. Mounting and Assembly
3.1. Mounting the drive
Directly to the forward
feed unit
A DDC 1 drive has a protection category of IP 65 and can be directly moun-
ted to the forward feed unit.
Cooling The units must be mounted in such a way that the flow of the cooling air is
not prevented from either entering or exiting the machine.
Safety distances The bleeder resistor in the DDC heats up during operations. Any flammable
materials or parts that could be affected by this hot air stream (e.g., PVC
cable ducts) should maintain a minimum distance of 300 mm to the air out-
let.
Fig 3.1: DDC with air inlet and outlet and position of the bleeder resistor
The DDC 1.1 generally requires no maintenace. If it is operated in a
highly polluted environment and the blower mesh and heatsinks are
at risk of becoming excessively dirty (e.g., with foundry dust), then
regular controls are recommended. If the operation of either the
blower or the heatsink are already affected by severe dirt, then
these must be cleaned.
SYSTEMKONFIGURATION
air outlet
rB= bending radius
rB
air inlet air inlet
air outlet
≥300
bleeder
heatsink
70
FPLufteinaus
air outlet
≥65 ≥65

3. Mounting and Assembly
• DOK-CONTRL-DDC+MDD+DLC-ANW1-EN-E1,44 • 01.97 19
3.2. Power connections of the DDC
The power connectors of the DDC (X7), the motor power connector (X5) and
the interface to the machine control (X8) on the DDC must be IP 65 connec-
tors.
The motor feedback cable and the connections of the optional plug-in modu-
les are inserted into the DDC.These are fed through the cable leadthroughs
on the underside of the DDC. Make sure that these are properly installed so
that the IP65 protection category of the DDC is in not negatively affected.
Fig 3.2: Installing cable leadthroughs
1. Release screw 1
2. Open cover shroud 2
3. Release knurled screw 3
4. Pull sheet-metal cover off 4
5. Remove gasket 5
6. Place cable in the gasket 5
7. Following instructions in reverse order
8. Screw 1 tightly into place until cable
leadthrough is totally sealed.
Installation guidelines
for cable leadthrough
EXDDC
2
5
3
14
DDC
6
6
Tighten the mounting bolts 6 of the protective shroud firmly into place.
Otherwise, the protection category IP 65 cannot be guaranteed.

3. Mounting and Assembly
• DOK-CONTRL-DDC+MDD+DLC-ANW1-EN-E1,44 • 01.97 20
3.3. DDC - dimensional data
Fig 3.3: Dimensional data - DDC 1.1
Protective shroud
air
inlet
25
(22.5)
140
space for
cable
775 (with blower)
470
635 (without blower)
air
inlet
145
65
40
Protective shroud
7
air outlet
165
(165)
9,5
7
13
(140)
7.5(10) 500
517.5 (without blower)
657.5 (with blower)
298
220
275
MBDDC
Motor power
connection
Mains conn.
Interface to
machine
controller
Interface to
machine
controller
110
27.5
160
45