Rexroth Indramat ECODRIVE03 Series Technical manual

Project Planning Manual
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SYSTEM200
ECODRIVE03
Drive Controllers

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ECODRIVE03
Drive Controllers
Project Planning Manual
DOK-ECODR3-DKC**.3****-PR05-EN-P
•Box 71 / 72 / 73
•Document Number, e.g. 120-1000-B307-05/EN
This documentation describes …
•planning the mechanical construction
•planning the electrical
•logistical handling of the equipment
•preparing the necessary equipment for startup operation
esaeleRnoitpircseD
Date
Notes
DOK-ECODR3-DKC**.3****-PRJ1-EN-P04.98 1st edition
DOK-ECODR3-DKC**.3****-PR03-EN-P 09.99 new edition
DOK-ECODR3-DKC**.3****-PR04-EN-P 05.00 revision
DOK-ECODR3-DKC**.3****-PR05-EN-P 02.02 revision
2002 Rexroth Indramat GmbH
Copying this document, giving it to others and the use or communication
of the contents thereof without express authority, are forbidden. Oenders
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 specied data is for product description purposes only and may not
be deemed to be guaranteed unless expressly conrmed in the contract.
All rights are reserved with respect to the content of this documentation
and the availability of the product.
Rexroth Indramat GmbH
Bgm.-Dr.-Nebel-Str. 2 •D-97816 Lohr a. Main
Telephone [phone] •Tx 689421 •Fax [phone]
http://www.boschrexroth.de/
Dept. EDH/EDY1 (RR/US)
This document has been printed on chlorine-free bleached paper.
Title
Type of Documentation
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Internal FileReference
Purpose of Documentation
Record of Revisions
Copyright
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Published by
Note
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Note:The following documentation is not required in its entirety for
project planning.
"Servo Applications with 1,5 s Acceleration Time"
- Selection lists -
DOK-ECODR3-SERV-GEN***-AUxx-MS-P
"Servo Applications with 400 ms Acceleration Time"
- Selection lists -
DOK-ECODR3-SERV-WZM***-AUxx-MS-P
"Main drives with 2AD-, ADF- and 1MB-motors"
- Selection lists -
DOK-ECODR3-MAIN*WZM***-AUxx-MS-P
"List of Connecting Cables for DIAX04 and ECODRIVE03"
- Selection lists -
DOK-CONNEC-CABLE*STAND-AUxx-EN-P
"ECODRIVE03 Drive for Machine Tool Applications With SERCOS-,
Analog- and Parallelinterface"
- Functional Description -
DOK-ECODR3-SMT-01VRS**-FKxx-EN-P
"ECODRIVE03 Drive for Machine Tool Applications With SERCOS-,
Analog- and Parallelinterface"
- Functional Description -
DOK-ECODR3-SMT-02VRS**-FKxx-EN-P
"ECODRIVE03 Drive for General Automation With SERCOS-, Analog-
and Parallelinterface"
- Functional Description -
DOK-ECODR3-SGP-01VRS**-FKxx-EN-P
"ECODRIVE03 Drive for General Automation With Fieldbus-Interfaces"
- Functional Description -
DOK-ECODR3-FGP-01VRS**-FKxx-EN-P
"ECODRIVE03 Drive for General Automation With Fieldbus-Interfaces"
- Functional Description -
DOK-ECODR3-FGP-02VRS**-FKxx-EN-P
Supplementary documentation
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"ECODRIVE03 Drive for General Automation With Fieldbus-Interfaces"
- Functional Description -
DOK-ECODR3-FGP-03VRS**-FKxx-EN-P
"LWL - Handling"
- Application Manual -
DOK-CONNEC-CABLE*LWL-AWxx-EN-P
"Electromagnetic Compatibility (EMC) in Drive and Control Systems"
- Project Planning Manual -
DOK-GENERL-EMV********-PRxx-EN-P
"Digital AC Motors MKD"
- Project Planning Manual -
DOK-MOTOR*-MKD********-PRxx-EN-P
"Digital AC Motors MHD"
- Project Planning Manual -
DOK-MOTOR*-MHD********-PRxx-EN-P
"MKE Digital AC Motors for potentially explosive areas"
- Project Planning Manual -
DOK-MOTOR*-MKE********-PRxx-EN-P
"2AD AC Motor"
- Project Planning Manual -
DOK-MOTOR*-2AD********-PRxx-EN-P
"ADF Main Spindle Motors"
- Project Planning Manual -
DOK-MOTOR*-ADF********-PRxx-EN-P
"1MB Frameless Spindle Motor"
- Project Planning Manual -
DOK-MOTOR*-1MB********-PRxx-EN-P
"Synchronous MBS Kit Spindle Motors"
- Project Planning Manual -
DOK-MOTOR*-MBS********-PRxx-EN-P
LAR 070-132 Geh äuse-Linearmotoren
- Selection and Project Planning -
DOK-MOTOR*-LAR********-AWxx-DE-P
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"LAF050 – 121 Linear Motors"
- Selection and Project Planning -
DOK-MOTOR*-LAF********-AWxx-EN-P
"Linear Synchronous Direct Drives LSF"
- Project Planning Manual -
DOK-MOTOR*-LSF********-PRxx-EN-P
"AC Drive Units in Personnel Conveyor Systems"
- Application Manual -
DOK-GENERL-ANTR*PERSON-ANxx-EN-P
"AC Drive Units in Hazardous Areas (Expl. Protection)"
- Application Manual -
DOK-GENERL-ANTR*EXPLOS-ANxx-EN-P
"ECODRIVE03 Drive for Machine Tool Applications With SERCOS-,
Analog- and Parallelinterface"
- Troubleshooting Guide -
DOK-ECODR3-SMT-01VRS**-WAR*-EN-P
"ECODRIVE03 Drive for Machine Tool Applications With SERCOS-,
Analog- and Parallelinterface"
- Troubleshooting Guide -
DOK-ECODR3-SMT-02VRS**-WAR*-EN-P
"ECODRIVE03 Drive for General Automation With SERCOS-, Analog-
and Parallelinterface"
- Troubleshooting Guide -
DOK-ECODR3-SGP-01VRS**-WAxx-EN-P
"ECODRIVE03 Drive for General Automation With Fieldbus-Interfaces"
- Troubleshooting Guide -
DOK-ECODR3-FGP-01VRS**-WAxx-EN-P
"ECODRIVE03 Drive for General Automation With Fieldbus-Interfaces"
- Troubleshooting Guide -
DOK-ECODR3-FGP-02VRS**-WAxx-EN-P
"ECODRIVE03 Drive for General Automation With Fieldbus-Interfaces"
- Troubleshooting Guide -
DOK-ECODR3-FGP-03VRS**-WAxx-EN-P
"DOLFI, Auxiliary for Download Firmware"
- Application Manual -
DOK-DOLFI DO01D**W
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Notes
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stnetnoCsrellortnoCevirD30EVIRDOCE I
Contents
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1.1 Drive package ECODRIVE03 ........................................................................................................ 1-1
1.2 An Overview of Individual Components of the ECODRIVE03 Family ........................................... 1-2
1.3 An Overview of Drive Controllers and Auxiliary Components........................................................ 1-3
An Overview of Communications Interfaces............................................................................ 1-3
An Overview of Measuring Systems Supported ...................................................................... 1-4
Type Code for Drive Controller DKC ....................................................................................... 1-5
Type Code Auxiliary Braking Resistor Module BZM................................................................ 1-6
Type Code for CZM Auxiliary Braking Resistor Module .......................................................... 1-6
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2.1 Appropriate use............................................................................................................. ................. 2-1
Introduction ................................................................................................................... ........... 2-1
Areas of use and application................................................................................................... . 2-2
2.2 Inappropriate use ........................................................................................................... ................ 2-2
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3.1 Introduction................................................................................................................ ..................... 3-1
3.2 Explanations................................................................................................................ ................... 3-1
3.3 Hazards by Improper Use ..................................................................................................... ......... 3-2
3.4 General Information ......................................................................................................... .............. 3-3
3.5 Protection Against Contact with Electrical Parts............................................................................ 3-5
3.6 Protection Against Electric Shock by Protective Low Voltage (PELV)........................................... 3-6
3.7 Protection Against Dangerous Movements.................................................................................... 3- 7
3.8 Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting .......... 3-9
3.9 Protection Against Contact with Hot Parts ................................................................................... 3-10
3.10 Protection During Handling and Mounting ................................................................................... 3 -10
3.11 Battery Safety............................................................................................................. .................. 3-11
3.12 Protection Against Pressurized Systems ..................................................................................... 3-11
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4.1 Technical Data ............................................................................................................................... 4-1
Dimensions.............................................................................................................................. 4-1
Ambient and operating conditions........................................................................................... 4-4
Electric Data of the Individual DKC**.3 Components.............................................................. 4-6
Storable energy in the bus..................................................................................................... 4-17
Mains supply options ........................................................................................................... .. 4-19
Number of ECODRIVE03 Units and Auxiliary Components on one DC bus......................... 4-20
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Selection criteria for supply options ....................................................................................... 4-2 1
Energy circuit DKC**.3 using "Central supply" as an example.............................................. 4-26
Allowed DC bus Peak Power................................................................................................. 4-27
Allowed DC bus continuous power without auxiliary components......................................... 4-28
Allowed DC bus continuous power with CZM01.3 auxiliary components.............................. 4-31
Allowed DC bus continuous power with CZM01.3 and GLD12 smoothing choke................. 4-34
Allowed DC bus continuous power with single-phase mains connection.............................. 4-36
CE label, C-UL listing, Tests .................................................................................................. 4-39
4.2 Electrical connections - independent of the drive controller type................................................. 4-40
A look at the drive controller and connector designations ..................................................... 4-40
Independent of the drive controller type – total connecting diagram..................................... 4-44
X1, Connections for Control voltage ...................................................................................... 4-45
X2, Serial Interface ................................................................................................................ 4-49
X3, Digital and analog I/Os .................................................................................................... 4-53
X4, Encoder 1 .................................................................................................................. ...... 4-59
X5, DC bus, Motor and Mains Connections........................................................................... 4-62
X6, Motor temperature monitoring and holding brakes ......................................................... 4-67
X7, Connection for Programming module.............................................................................. 4-73
X8, Encoder 2 .................................................................................................................. ...... 4-75
X9, Incremental and Absolute Encoder Emulation (SSI format)........................................... 4-81
X10, EcoX Expansion interface ............................................................................................. 4-86
X11, DC bus dynamic brake (ZKS), U Dpower supply ........................................................... 4-88
X12, Optional Choke Connection for DKC**.3-200-7 ............................................................ 4-93
XE1, XE2 Protective conductor connections for motor and mains........................................ 4-95
XS1, XS2, XS3 Shield Connections ...................................................................................... 4-96
4.3 Electrical Connections – dependent on the drive controller type................................................. 4-97
DKC 01.3-***-7-FW – Parallel Interface................................................................................. 4-97
DKC 02.3-***-7-FW – SERCOS interface............................................................................ 4-104
DKC 03.3-***-7-FW – Probus-DP Interface ....................................................................... 4-108
DKC 04.3-***-7-FW – InterBus Interface ............................................................................. 4-114
DKC 05.3-***-7-FW – CANopen Interface ........................................................................... 4-117
DKC 06.3-***-7-FW – DeviceNet Interface .......................................................................... 4-119
DKC 11.3-***-7-FW – Analog Interface................................................................................ 4-121
DKC 21.3-***-7-FW – Parallel Interface 2............................................................................ 4-121
DKC 22.3-***-7-FW – SERCOS interface............................................................................ 4-125
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5.1 Technical Data .............................................................................................................. ................. 5-1
Dimensions ..................................................................................................................... ......... 5-1
Materials used, Mass ........................................................................................................... .... 5-2
Ambient and operating conditions........................................................................................... 5-3
Electric Data of the Individual DKC**.3-016 Components ....................................................... 5-4
Storable energy in the bus..................................................................................................... .. 5-9
Mains supply options ........................................................................................................... .. 5-10
Allowed DC bus Peak Power................................................................................................. 5-12
Allowed DC bus continuous power........................................................................................ 5-12
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Allowed DC bus continuous power with single-phase mains connection.............................. 5-13
CE label, C-UL listing, Tests.................................................................................................. 5-15
5.2 Electrical connections.................................................................................................................. 5-16
A look at the drive controller and connector designations ..................................................... 5-16
Independent of the drive controller type – total connecting diagram..................................... 5-18
X1, Connections for control voltage....................................................................................... 5-19
X2, Serial Interface ................................................................................................................ 5-23
X3, Digital I/Os ....................................................................................................................... 5-25
X4, Encoder 1 .................................................................................................................. ...... 5-29
X5, Motor and Mains Connections......................................................................................... 5-32
X6, Motor temperature monitoring and holding brakes ......................................................... 5-36
X10, EcoX Expansion interface ............................................................................................. 5-41
XE1, XE2 Protective conductor connections for motor and mains........................................ 5-42
XS1, XS2, XS3 Shield Connections ...................................................................................... 5-43
H1, S1, S2, S3:Diagnostic display, Reset key, Address switch............................................ 5-44
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6.1 General..................................................................................................................... ...................... 6-1
6.2 Technical data.............................................................................................................. .................. 6-1
Dimensions ..................................................................................................................... ......... 6-1
Materials used, Mass ........................................................................................................... .... 6-2
Ambient and operating conditions........................................................................................... 6-3
Electrical data of auxiliary component BZM01.3...................................................................... 6-3
CE Label, Tests ................................................................................................................ ....... 6-5
6.3 Electrical Connections BZM01.3.................................................................................................... 6-6
Front View..................................................................................................................... ........... 6-6
Complete Terminal Diagram.................................................................................................... 6- 7
X1, Control voltage connections.............................................................................................. 6- 9
X2, DC bus dynamic brake (ZKS), Diagnostic Signals.......................................................... 6-11
X3, RS 232 Interface........................................................................................................... ... 6-17
X5, DC bus and Mains connection ........................................................................................ 6-17
XE1, Protective conductor connection for mains................................................................... 6-20
XS1, XS2, Shield connections............................................................................................... 6-20
Diagnostic LEDs and Reset Probe ........................................................................................ 6-21
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7.1 General..................................................................................................................... ...................... 7-1
7.2 Technical data.............................................................................................................. .................. 7-2
Dimensions ..................................................................................................................... ......... 7-2
Materials used, Mass ........................................................................................................... .... 7-3
Ambient and operating conditions........................................................................................... 7-3
Electrical Data of Auxiliary Component CZM01.3.................................................................... 7-3
CE Label, Tests ................................................................................................................ ....... 7-4
7.3 Electrical Connections of CZM01.3................................................................................................ 7-5
Front View..................................................................................................................... ........... 7-5
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IV srellortnoCevirD30EVIRDOCEstnetnoC
X5, DC bus connection .......................................................................................................... .. 7-6
XE1, Protective conductor connection for mains..................................................................... 7-8
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8.1 General..................................................................................................................... ...................... 8-1
8.2 Dimensions and Mounting Dimensions.......................................................................................... 8-1
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9.1 Application recommendations........................................................................................................ 9-1
9.2 Technical data................................................................................................................................ 9-1
9.3 Dimensional sheets and installation dimensions........................................................................... 9-2
9.4 Front views................................................................................................................. .................... 9-2
9.5 Electrical connection ....................................................................................................... ............... 9-3
9.6 Type code................................................................................................................... .................... 9-4
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10.1 Selection.................................................................................................................. ..................... 10-1
10.2 Autotransformers for Drive Controllers ..................................................................................... ...10-1
10.3 Type code.................................................................................................................. ................... 10-4
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11.1 General.................................................................................................................... ..................... 11-1
11.2 The Ground Conditions of the Power Supply Network ................................................................ 11-1
11.3 Earth-leakage circuit breaker .............................................................................................. ......... 11-2
11.4 Control Circuits for the Mains Connection ...................................................................................11-2
Control Circuits with E-Stop...................................................................................................11-3
Control Circuits with internal DC bus dynamic brake (ZKS)..................................................11-5
11.5 Mains Contactor / Fuses .................................................................................................... ..........11-7
Computing phase current on the mains.................................................................................11-7
Computing charging current inrush........................................................................................11-8
Factor F for Computing the Connected Load ........................................................................11-9
Q1 Fuse and K1 Contactor ..................................................................................................11-12
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12.1 Notes on Control Cabinet Project Planning ................................................................................. 1 2-1
Power dissipation.............................................................................................................. .....12-1
Mounting Position and Distances ..........................................................................................12-6
Module widths......................................................................................................................12-11
Arranging ECODRIVE03 Components in the Control Cabinet............................................12-12
12.2 Using Cooling Units in the Control Cabinet................................................................................ 1 2-14
12.3 General Notes .............................................................................................................. .............. 12-16
12.4 Wire routing in the Control Cabinet............................................................................................12-17
12.5 EMC in the Control Cabinet.......................................................................................................12-17
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13.1 Packaging.................................................................................................................. ................... 13-1
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