Mannesmann Rexroth DKR02 Project Planning Manual Download Page 94

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10-8

Mounting and installation

DKR Drive Controllers

DOK-DIAX03-DKR********-PR02-EN-P

MontDKR

DIA

X03

KR0

Fig. 10-6:

Mounting the DKR04 with mounting frame (Cooling method: with air

from outside the control cabinet)

LSA Control S.L. www.lsa-control.com [email protected] (+34) 960 62 43 01

Summary of Contents for DKR02

Page 1: ...and DKR04 Drive Controllers Project Planning Manual DOK DIAX03 DKR PR02 EN P mannesmann Rexroth engineering Indramat Rexroth SYSTEM200 LSA Control S L www lsa control com comercial lsa control com 34...

Page 2: ...n a separate documentation 2000 Rexroth Indramat GmbH Copying this document giving it to others and the use or communication of the contents thereof without express authority are forbidden Offenders a...

Page 3: ...igital intelligent drive controllers Project Planning Manual DOK DIAX03 PLUG IN MOD PRxx EN P 275 155 DIAX03 AC Drives for Continuous Operation S1 Selection data DOK DIAX03 PRIN AUxx EN P 274 660 DIAX...

Page 4: ...resistor DZB included Entire document data regarding other units than the ones described in this documentation replaced by cross references cables motors plug in modules Sales Service Facilities inclu...

Page 5: ...movements 2 6 2 8 Protection against magnetic and electromagnetic fields during operations and mounting 2 8 2 9 Protection against contact with hot parts 2 9 2 10 Protection during handling and insta...

Page 6: ...s 6 12 Overvoltage suppressor 6 13 6 6 Functions and allocations of individual interfaces 6 14 X2 Serial interface 6 14 X3 Analog output and signal contact 6 16 X4 Motor feedback 6 17 X6 Monitoring mo...

Page 7: ...Mounting the drive 10 6 10 3 Drive wiring 10 9 Power connector with double cable 10 10 11 Service and checks 11 1 11 1 Error diagnoses 11 1 11 2 Repairing and replacing units 11 2 11 3 Fault report 1...

Page 8: ...IV Contents DKR Drive Controllers DOK DIAX03 DKR PR02 EN P Notes LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01...

Page 9: ...t of damages resulting from inappropriate use are forfeited The user alone carries all responsibility of the risks Before using Rexroth Indramat products make sure that all the pre requisites for an a...

Page 10: ...rollers are available with differing drive power and different interfaces Typical applications of DKR drive controllers are printing machines and NC machine tools The drive controllers may only be ope...

Page 11: ...le for the safe operation of this equipment If the product is resold rented or transferred or passed on to others then these safety instructions must be delivered with the product WARNING Inappropriat...

Page 12: ...wrong connections Danger to life severe electrical shock and severe bodily injury WARNING Health hazard for persons with heart pacemakers metal implants and hearing aids in proximity to electrical equ...

Page 13: ...designed for installation on commercial machinery European countries see directive 89 392 EEC machine guideline The ambient conditions given in the product documentation must be observed Use only saf...

Page 14: ...e potentials higher than 50 V the equipment must be disconnected from the mains voltage or power supply The following should be observed with electrical drives power supplies and filter components Wai...

Page 15: ...ical equipment and units must always be firmly connected to the supply network Use a copper conductor with at least 10 mm cross section over its entire course for this protective connection Prior to s...

Page 16: ...g transformer an opto electronic coupler or when battery operated 2 7 Protection against dangerous movements Dangerous movements can be caused by faulty control or the connected motors These causes ar...

Page 17: ...es use protective railings install protective coverings install light curtains or light barriers Fences must be strong enough to withstand maximum possible momentum Mount the emergency stop switch E s...

Page 18: ...esent a serious health hazard to persons with heart pacemakers metal implants and hearing aids WARNING Health hazard for persons with heart pacemakers metal implants and hearing aids in proximity to e...

Page 19: ...nstallation of parts and components may cause injuries CAUTION Risk of injury through incorrect handling Bodily harm caused by crushing shearing cutting and mechanical shock Observe general instructio...

Page 20: ...ADS ADM 1MB etc and drives corresponding to the information in the Project Planning manual must be provided with and remain under a forced load such as compressed air hydraulic oil cooling fluid or c...

Page 21: ...MB and linear motors LSF or LAF The output of these motors is between 10 and 93 kW of continuous power at the motor output shaft For precise control and regulation of the motors there are DKR drive co...

Page 22: ...l enclosure or cooling with a duct Various components i e modules are available for insertion into the basic unit of the DKR It is by means of these components that the DKR can be adapted to a specifi...

Page 23: ...irmware in terms of the configuration selected and the features It is dependent on them In the event that the unit must be replaced all existing drive parameters can be transmitted to the replacement...

Page 24: ...ems incremental measuring systems with square wave signal output incremental measuring systems with sinusoidal signal output singleturn encoder measuring systems multiturn absolute encoders with SSI s...

Page 25: ...connect a brake resistor type DZB01 1 W720N The electronic control system for the brake resistor is situated in the drive controller of the devices equipped with this option The brake resistor itself...

Page 26: ...3 6 Introducing the devices DKR Drive Controllers DOK DIAX03 DKR PR02 EN P Notes LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01...

Page 27: ...3 Peak power of the drive 4 kHz 8 kHz as relates to the driven shaft of motor at 3xAC 400 V 5 Pmax kW ca 55 ca 93 Continuous regenerated power Pr ck kW ca 37 ca 43 Peak regenerated power max 10 s as r...

Page 28: ...rol voltage power PN2 VA 200 Continuous current of the drive 4 kHz 8 kHz Iconteff A 4 kHz 71 8 kHz 60 4 kHz 92 8 kHz 78 Peak current of the drive Imaxeff A 71 141 Continuous power of the drive 4 kHz 8...

Page 29: ...r m kg approx 49 Accessories kit M1 RAC 3 m kg 1 7 Ambient conditions Perm ambient temp range with rated data TA1 C 5 45 Max perm ambient temp with derating of nominal data to 80 TA2 C 55 Storage and...

Page 30: ...W ca 92 ca 125 Continuous regenerated power Pr ck kW ca 58 ca 66 Peak regenerated power max 10 s as relates to the driven shaft of motor Pr ckmax kW ca 92 ca 125 Drive controller power voltage Ueff V...

Page 31: ...wer UL V DC 24 V 20 Current of the blower IL A 0 22 Weight Auxiliary brake resistor m kg 15 3 Ambient conditions Perm ambient temp range with rated data TA1 C 5 45 Max perm ambient temp with derating...

Page 32: ...4 6 Technical data DKR Drive Controllers DOK DIAX03 DKR PR02 EN P Notes LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01...

Page 33: ...than the specified ones might be damaged Any claim under guarantee will expire CAUTION Damage caused by overloading of the drive controller In case you want to use the drive controllers for others th...

Page 34: ...our application The drive itself meets the requirements set for protection category IP20 as defined in EN 60 529 edition dated 10 91 DIN VDE 0470 1 The drive controller has been designed for mounting...

Page 35: ...ed air flow data and noise emissions The energy dissipated both internally and externally is load dependent To correctly dimension the cabinet or cooling equipment it is necessary to know the individu...

Page 36: ...et CAUTION Damage to the drive controller by intake of polluted air outside the control cabinet The intake for the air outside the control cabinet mustn t be situated near the machining room in order...

Page 37: ...or outside the cabinet If the drive controller is cooled via duct the air flow is taken in and out by two different ducts This cooling method is recommended if it is impossible to position the vents...

Page 38: ...TM TM BR 0VB X6 air outlet air inlet Fig 5 5 Cooling method via duct the example shown is a DKR03 Cooling with air from outside the cabinet or with a duct affects the protection category of the cabin...

Page 39: ...densation water cannot drip onto the electronic equipment within the cabinet Construct the heat exchanger in such a way that the blower of the heat exchanger cannot spray onto the electronic equipment...

Page 40: ...inside temperature of the control cabinet is not lower than the outside temperature Set the temperature limit to 40 C Use only sealed cabinets If the cabinet is poorly sealed then moisture condensate...

Page 41: ...ndicated mounting positions Required distances for cooling with air from inside the cabinet zMILKDKR min 160 mm min 160 mm air outlet air inlet DIAX03 DKR0 3 H1 X4 X2 U5 U3 S2 U4 U1 U2 X9 1 6 1 7 X8 H...

Page 42: ...et option air outlet option DIAX03 DKR02 430 1000 H1 X4 X2 U5 U2 S2 U4 U1 U3 X9 1 6 1 7 X8 H2 S1 X3 X7 1 10 1 11 X3 Netz Mains L3 L2 L1 Motor A3 A1 A2 220V Steuer spannung Aux Voltage B2 B1 N L L L 27...

Page 43: ...tside the unit zMALKDKR2 115 0 5 63 M8 68 0 5 R 1 0 869 976 1 176 0 5 157 0 5 185 270 0 5 135 68 R 1 0 Looking from outside of control enclosure onto rear wall or mounting panel All dimensions in mm m...

Page 44: ...5 80 668 690 10 310 MBDKR3 H1 X4 X2 U5 U3 S2 U4 U1 U2 X9 1 6 1 7 X8 H2 S1 X3 X7 1 10 1 11 X3 air inlet option air outlet option Netz Mains L3 L2 L1 Motor A3 A1 A2 B2 B1 220V Steuerspannun g Aux Volta...

Page 45: ...tside the unit zMALKDKR3 115 0 5 39 M8 68 0 5 R 1 0 559 668 1 176 0 5 157 0 5 185 210 0 5 110 69 R 1 0 min 80 mm min 80 air outlet air inlet min 80 mm M8 M8 Control enclosure rear wall or mounting pan...

Page 46: ...it dimensions MBDKR4 DIAX03 DKR04 571 560 460 50 4 17 1080 13 500 30 12 for M10 mains connection screw M12 motor power connection screw M12 150 315 grounding bolts screw M12 H1 X4 X2 U5 U2 S2 U4 U1 U3...

Page 47: ...ide the unit 11 0 2 5 2 0 2 4x 4x 460 0 5 360 0 5 264 20 zMalkDKR4 806 165 1050 0 5 110 360 0 5 500 0 5 40 min 80 mm air outlet air inlet min 80 mm min 80 mm Looking from outside of control enclosure...

Page 48: ...R PR02 EN P DZB01 Unit dimensions free space 440 460 480 6 5 200 200 100 INDRAMAT Type kW Amp ED bei 120s Spield W Nr Nr Last R1 R2 blower 50 50 90 130 Fig 5 15 Unit dimensions DZB01 LSA Control S L w...

Page 49: ...air inlet 93 63 260 min 183 air outlet zMSchDKR 110 119 air inlet air outlet duct 80 part no 239312 flange adapter for duct cooling duct 125 part no 238354 flange 2 all dimensions in mm ducts must be...

Page 50: ...2 25 1 6 X9 1 7 X8 1 10 X7 1 11 X3 X3 H2 S1 U1 U3 U4 U5 U2 S2 X4 X2 H1 mind 365 156 closed mounting panel without vents DIAX03 DKR 04 Fig 5 17 Additional dimensions when cooling with a duct DKR04 Note...

Page 51: ...BFL1DKR 7 165 195 68 35 60 2 121 125 5 15 all dimensions in mm Fig 5 18 Flange 2 MBFL2DKR 45 0 3 80 5 0 2 100 0 5 91 0 5 4 5 7 9 146 0 2 117 0 1 14 5 79 0 1 6 all dimensions in mm Fig 5 19 Flange LSA...

Page 52: ...s e g feedback or NC connections or isolate the cable channel metallically see illustration below metallic cable channel KabDKR 2 4 mm 100 mm plastic cable channel Fig 5 20 Various cable channels Cont...

Page 53: ...and intermediate coupler units In addition the following notes apply to the indicated lengths of the leads Note The lengths given apply to direct connections between drive and motor without clamping p...

Page 54: ...lding effects Do not use varistors as protective circuits If high frequency equipment is used in the plant e g components of anodizing equipment then situate and wire such equipment outside of the cab...

Page 55: ...ys connect the drive to the grounded conductor system of the mains or the cabinet Note the details on this in section 6 4 Twist the strands of motor power cables Analog signals must be conducted via s...

Page 56: ...VW K1NO K1NC X7 mains connection X5 motor power connection X5 connection X6 for motor temperature monitoring motor holding brake connection for control voltage option terminals X10 control inputs ON O...

Page 57: ...nterface connecting the optional plug in mudules as per the relvant diagrams U1 U5 software module DSM X8 U3 U4 1 2 3 4 5 3 x AC 400 480 V 50 60 Hz grounded mains N L K control voltage AC 230 V 50 60...

Page 58: ...connectors of the drive X5 L1 L2 L3 3xAC 400 480 V 10 50 60 Hz 2 Hz X10 L N 1xAC 230 V 10 50 60 Hz 200 VA or 300 VA The devices are type tested according to EN61 800 3 industrial area i e the voltage...

Page 59: ...al currents of fuses and transformer if necessary Ungrounded three phase system CAUTION Damage to persons or property caused by overvoltage between phase conductor and housing Only connect the drive c...

Page 60: ...the use of an overvoltage suppressor Note The information on page 6 13 will help you select appropriate overvoltage suppressors Note Operating the drive with an overvoltage suppressor does not offer...

Page 61: ...0 75 2 5 mm 2 remote trigger F2 F1 F3 F2 main switch of machine 230 V 10 50 60 Hz NFD drops off if voltage does not need to be matched drops off with AC 230 V control enclosure grounding potential pow...

Page 62: ...ntial bridge removed power circuit breaker drops off if voltage does not need to be matched power circuit breaker For primary protection of transformers with a high degree of inrush peak e g Siemens 3...

Page 63: ...fuse F1 type Minimum lead cross section in mm DKR03 1 100 3 x NH25gl 4 DKR03 1 200 3 x NH35gl 6 DKR02 1 200 3 x NH50gl 10 DKR02 1 300 3 x NH63gl 16 DKR04 1 300 3 x NH80gl 25 DKR04 1 400 3 x NH80gl 25...

Page 64: ...erature at the machine Current load table Conversion table for ambient temperatures above 30 C rated cross section of the leads in m Current load of leads on machines with normal applications in the c...

Page 65: ...DKR Netz I U S 3 INetzDKR mains current A PDauerMotor actual continuous power of the motor kW SNetz power of the autotransformer kVA UNetzDKR mains voltage V Fig 6 11 Formula to determine the power of...

Page 66: ...11 Make sure that the power of the isolating transformer as dependent upon the drive does not drop below the values listed in the following table Type of drive controller Minimum power of the isolatin...

Page 67: ...nts equal to I t 750 A s 30 s with 5 A For thermal reasons higher leakage currents trigger the signal contact The overvoltage suppressors are as a result defective and must then be replaced o Type of...

Page 68: ...lectromagnetic Compatibility EMC in Drive and Control Systems RS 232 interface The RS 232 interface enables a maximum number of participants of 1 i e when using DriveTop only one drive can be paramete...

Page 69: ...card in PC Note Please contact your PC supplier to find the solution for your application X2 4 RS485 5 RS485 7 SGND 12 5V 1 2 3 1 2 3 X1 X2 Axis 1 X2 4 5 7 12 1 2 3 1 2 3 X1 X2 PC 1 RS 485 1 2 2 3 3...

Page 70: ...ring functions are signaling that they are in proper working order The drive is than ready for power ON In the event of a malfunction the contact opens and the internal power contactor drops off if P...

Page 71: ...edback please consider the following aspects Use feedback cable assembly manufactured by Rexroth Indramat Note the maximum cable length of 75 meters Rexroth Indramat cable Operate only those motor dri...

Page 72: ...the motor temperature monitoring and the holding brake devices For detailed information see the relevant motor documentation Maximum cable length 75 meters Rexroth Indramat cable DANGER Dangerous mov...

Page 73: ...kt acknowledge power ON auxiliary contact of K1 emergency bleeder working power contactor pulled up power contactor dropped off Fig 6 19 Signal outputs at X7 CAUTION Malfunction of the installation ca...

Page 74: ...voltages SBX8DKR 1 2 3 4 5 6 7 X8 Inside the unit Connection outside the unit max core cross section 2 5 mm2 15 VM measuring voltage 0 VM reference potential of measuring voltage 15 VM measuring volt...

Page 75: ...on Description for details When the ON contact is activated the internal power contactor is switched on if the OFF contact is closed and a machine internal ready state is being signaled see Bb1 contac...

Page 76: ...evices cannot be operated without DZB01 1 If you try to operate an E device without DZB01 1 the controller stops with the error message F820 Braking resistor overload INDRAMAT Type kW Amp ED bei 120s...

Page 77: ...nnectors as depicted in the illustration below are part of this connector kit S1DKR fh7 X4 part no 231715 Connector for motor feedback connection is generally included in the accessories kit for confi...

Page 78: ...the topicality connector kits are not listed in this documentation For assistance in determining the correct connector set for a specific application please consult your Rexroth Indramat Sales Represe...

Page 79: ...age N L K X5 X10 TM TM BR 0VB X6 for routing internal to the control enclosure SERDKR fibre optic cable rings CNC SERCOS interface Fibre optic cable plug in coupling unit control enclosure leadthrough...

Page 80: ...3 The conversion accessories for the DKR04 drive are in the accessory kit M2 RAC2 The ducts must be ordered separately see chapter 5 4 Fig 5 16 and Fig 5 17 Mounting frames In order to stabilize thin...

Page 81: ...in modules for example in packaging that is capable of conducting such loads 8 2 Storage CAUTION Damage to property caused by inappropriate storage When choosing the place of storage observe the admis...

Page 82: ...8 2 Transport and storage DKR Drive Controllers DOK DIAX03 DKR PR02 EN P Notes LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01...

Page 83: ...y slip or freight documentation 9 2 Delivery slip and barcode sticker The delivery slip lists the merchandise of the entire delivery in terms of the names of the item and the order designations There...

Page 84: ...vide service information In addition there is a rating plate on the drive controller that helps you identify the software stored in the software module X9 1 6 1 7 X8 X7 1 10 1 11 PosTSDKR DIAX03 DKR03...

Page 85: ...n slot Fig 9 3 Example Configuration plate DKR D K R 4 1 W 3 0 Example 1 2 3 4 Product groupe Line Design Cooling mode Liquid F Air buil in blower W Rated current Bleeder without bleeder standard N wi...

Page 86: ...xiliary bleeders D Z B 1 1 W 7 2 Example 1 2 3 4 Product groupe Line Version Cooling mode air internal by build in blower W Brake energy 720 kWs 720 Nominal voltage blower DC 24 V N 0 N 0 TLDZB fh7 5...

Page 87: ...sink in the mounting panel of the control cabinet the air openings on the top and bottom side of the device to be replaced are closed with covers which shows that the device was being operated with ai...

Page 88: ...L2 L1 Mo tor A3 A1 A2 B2 B1 220 V Ste uer spa nnu ng Au x Vo ltag e N L K X5 X1 0 TM TM BR 0VB X6 LUFTDKR3 FH7 cover 1 cover 2 as delivered side view as mounted side view conversion perspective air ou...

Page 89: ...LLER DKR 3 H1 X4 X2 U5 U2 S2 U4 U1 U3 X9 1 6 1 7 X8 H2 S1 X3 X7 1 10 1 11 X3 Ne tz M ains L3 L2 L1 Motor A3 A1 A2 B2 B1 22 0V Steu ersp an nu n g Au x Vo ltage N L K X5 X1 0 TM TM BR 0VB X6 USchDKR 1...

Page 90: ...control cabinet maker For the conversion to Cooling with air from inside the cabinet there are no additional parts required it is only necessary to dismount installed parts 1 Remove the round cover 1...

Page 91: ...lease proceed as follows 1 Remove the round cover 1 on the right side of the device 2 Remove the cover of the heatsink 2 on the bottom side of the device The screws are accessible from below 3 Mount t...

Page 92: ...duct vents in the back of the mounting supports and flange duct with 80 respectively 125 mm inside diameter Note Ducts are not included in the order They must be ordered separately and can be ordered...

Page 93: ...1 6 1 7 X8 H2 S1 X3 X7 1 10 1 11 X3 Ne tz Ma ins L3 L2 L1 Mo tor A3 A1 A2 B2 B1 22 0V Ste ue rsp an nu ng Au x Vo ltag e N L K X5 X1 0 TM TM BR 0VB X6 Fig 10 5 An example for mounting the DKR02 DKR03...

Page 94: ...N P MontDKR H1 X4 X2 U5 U2 S2 U4 U1 U3 X9 1 6 1 7 X8 H2 S1 X3 X7 1 10 1 11 X3 DIAX03 DKR04 Fig 10 6 Mounting the DKR04 with mounting frame Cooling method with air from outside the control cabinet LSA...

Page 95: ...rk an electrician must check using appropriate measuring equipment whether there is any residual voltage in the cabinet or in any of the parts e g from capacitors Wait their discharge time WARNING Dam...

Page 96: ...scharges the human body Place parts and tools on a grounded surface only Use a grounded soldering ironing when soldering Power connector with double cable The figure below shows a possibility to conne...

Page 97: ...pter 9 3 If you are not able to resolve a problem then it is recommended that you contact Rexroth Indramat Customer Service You will find the telephone number in chapter 13 For a rapid and proper hand...

Page 98: ...ctrical and mechanical connections except for the fixing screws for the device on the front top and bottom of the device In case of cooling with a duct remove the ducts from the duct adapters The cool...

Page 99: ...for installation By means of appropriate hoisting gear attach the drive controller to the loosened fixing screws Tighten the screws In accordance with the machine manufacturer s specification reestabl...

Page 100: ...ne at which problem occured Please describe the problem Machine manufacturer Machine no Type Op hours Commissioning date Manufacturer and type of machine controller Designation of machine axis in whic...

Page 101: ...VW contact brake resistor 3 5 6 22 ambient conditions 4 5 technical data 4 5 type code 9 4 unit dimensions 5 16 brake resistor in DKR02 technical data 4 1 brake resistor in DKR03 technical data 4 3 C...

Page 102: ...3 error messages 11 1 F firmware 3 2 firmware module 3 3 G grounded conductor 6 1 H holding brake see motor holding brake hotline 11 1 I identify basic unit see rating plate inappropriate use 1 2 con...

Page 103: ...S safety instructions for electric servo drives and controls 2 1 SERCOS interface 7 3 serial interface 6 14 shock resistance 5 2 signal contact 6 16 6 19 signal voltages 6 20 starting lockout 6 17 T t...

Page 104: ...12 4 Index DKR Drive Controllers DOK DIAX03 DKR PR02 EN P LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01...

Page 105: ...de Au erhalb Deutschlands nehmen Sie bitte zuerst Kontakt mit Ihrem lokalen Ansprechpartner auf Die Adressen sind im Anhang aufgef hrt Further hints about service repairs and training are available in...

Page 106: ...South West Mannesmann Rexroth AG Vertrieb Deutschland VD BI Gesch ftsbereich Rexroth Indramat Regionalzentrum S dwest Ringstrasse 70 Postfach 1144 70736 Fellbach 70701 Fellbach Tel 49 0 711 57 61 100...

Page 107: ...elefon 39 049 8 70 13 70 Telefax 39 049 8 70 13 77 Italy Mannesmann Rexroth S p A Divisione Rexroth Indramat Via Mascia 1 80053 Castellamare di Stabia NA Telefon 39 081 8 71 57 00 Telefax 39 081 8 71...

Page 108: ...roth Indramat Division Plot A 58 TTC Industrial Area Thane Turbhe Midc Road Mahape Village Navi Mumbai 400 701 Telefon 91 0 22 7 61 46 22 Telefax 91 0 22 7 68 15 31 India Mannesmann Rexroth India Ltd...

Page 109: ...a L7M 1A8 Telefon 1 905 335 55 11 Telefax 1 905 335 41 84 Canada West Basic Automation Burnaby 5345 Goring St Burnaby British Columbia Canada V7J 1R1 Tel 1 604 205 5777 Fax 1 604 205 6944 dave gunby b...

Page 110: ...13 6 Service Support DKR Drive Controllers DOK DIAX03 DKR PR02 EN P Notes LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01...

Page 111: ...LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01...

Page 112: ...Printed in Germany 2 6 6 6 2 6 LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01...

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