Rexroth Indramat BZM 01.3-01-07 Project Planning Manual Download

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ECODRIVE03 Drive Controllers

Replacing or Exchanging Drive Components

15-3

15.2 Procedure on Replacing the Unit

Note:

Note the safety instructions in section 3 when exchanging any

parts!

Replacing the drive controller

•

Make sure the drive controller is completely de-energized.

•

Switch main switch off.

•

Secure against being switched back on.

DANGER

Lethal electric shock caused by charged

capacitor!

Prior to touching bear connecting cables and

terminals, wait for the capacitor to discharge! Only

then work on the cables!

•

Remove contact protection and separate connecting line from the

drive controller.

•

Release screws on top and bottom of housing.

•

Remove the drive controller.

•

Insert programming module from defective drive controller into new

one. This eliminates the reloading of parameter files. If the

programming module is defective, see "Replacing Firmware" on

page 15-7.

•

Hand new drive controller into place and tighten screws.

•

Connect drive controller as specified in the machine terminal

diagrams.

•

Start up installation.

[email protected]

(479) 422-0390

Summary of Contents for BZM 01.3-01-07

Page 1: ...Project Planning Manual customerservice hyperdynesystems com 479 422 0390 SYSTEM200 ECODRIVE03 Drive Controllers...

Page 2: ...communication of the contents thereof without express authority are forbidden Offenders are liable for the payment of damages All rights are reserved in the event of the grant of a patent or the regis...

Page 3: ...D 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...

Page 4: ...nual 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...

Page 5: ...ODR3 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 Automat...

Page 6: ...s r e l l o r t n o C e v i r D 3 0 E V I R D O C E n o i t a t n e m u c o D s i h t t u o b A Notes customerservice hyperdynesystems com 479 422 0390...

Page 7: ...s n o i t c u r t s n I y t e f a S 3 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...

Page 8: ...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 D power supply...

Page 9: ...d e e l B y r a i l i x u A 3 0 E V I R D O C E 6 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 compon...

Page 10: ...cuit 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 Com...

Page 11: ...ant to supply and regeneration 16 1 Requirements 16 1 Calculations with regard to the power and energy allowed on the device side 16 2 Calculations with regard to the power and energy resulting on the...

Page 12: ...ndex 17 1 1 8 1 t r o p p u S e c i v r e S 8 1 18 1 Helpdesk 18 1 18 2 Service Hotline 18 1 18 3 Internet 18 1 18 4 Vor der Kontaktaufnahme Before contacting us 18 1 18 5 Kundenbetreuungsstellen Sale...

Page 13: ...m ECODRIVE03 is the cost effective solution with a high level of functionality for single and multiple axis drive and control tasks ECODRIVE03 can be used to implement a variety of drive tasks in the...

Page 14: ...hown in gray are absolutely necessary mains voltage DC 24 V fuse line contactor drive controller auxiliary bleeder module auxiliary capacitance module IKS ready made feedback cable AC motor IKG ready...

Page 15: ...DKC05 3 DKC06 3 Interface RS232 RS485 X X X X X X X X X Analog Interface X X X X X X X X X Parallel Interface X Parallel Interface 2 X Stepper Interface X SERCOS interface X SERCOS interface 2 X Prof...

Page 16: ...urn resolver RSF with feedback data storage FDS 3 resolver or multi turn resolver RSF without feedback data storage FDS 4 incremental measuring system with sine signals 1Vss signals 5 absolute measuri...

Page 17: ...lds Example 3 7 FW Voltage category Firmware Version A firmware specifying the functions of the drive must be ordered separately xx Series Type current 40 A 100 A 040 100 200 200 A 16 A 016 Fig 1 5 Ty...

Page 18: ...power 1 0 kW Version Series Auxiliary bleeder module TL0202F1 FH7 BZM 01 3 01 07 Type codes Example Fig 1 6 Type Code Type Code for CZM Auxiliary Braking Resistor Module CZM 01 3 02 07 Voltage catego...

Page 19: ...tee and the right to payment 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...

Page 20: ...ation specific use the drive controllers are available with differing drive power and different interfaces Typical applications of drive controllers belonging to the ECODRIVE03 family are handling and...

Page 21: ...r the safe operation of this equipment If the equipment is resold rented or transferred or passed on to others then these safety instructions must be delivered with the equipment WARNING Improper use...

Page 22: ...ue to wrong connections Danger to life or bodily harm by electric shock WARNING Health hazard for persons with heart pacemakers metal implants and hearing aids in proximity to electrical equipment CAU...

Page 23: ...by the manufacturer Follow all safety regulations and requirements for the specific application as practiced in the country of use The equipment is designed for installation in industrial machinery T...

Page 24: ...rdance with EMC requirements can be found in the documentation EMC in Drive and Control Systems The machine or installation manufacturer is responsible for compliance with the limiting values as presc...

Page 25: ...ts if the ground wire is not permanently connected to the points of the components provided for this purpose Before working with electrical parts with voltage higher than 50 V the equipment must be di...

Page 26: ...ps even for brief tests always connect the protective conductor or connect with ground wire Otherwise high voltages can occur on the housing that lead to electric shock 3 6 Protection Against Electric...

Page 27: ...Dangerous movements can occur immediately after equipment is switched on or even after an unspecified time of trouble free operation The monitoring in the drive components will normally be sufficient...

Page 28: ...cially if there is a possibility of loose parts flying off Mount the emergency stop switch in the immediate reach of the operator Verify that the emergency stop works before startup Don t operate the...

Page 29: ...ts in motors represent 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...

Page 30: ...orrect handling and mounting of parts and components may cause injuries CAUTION Risk of injury by incorrect handling Bodily harm caused by crushing shearing cutting and mechanical shock Observe genera...

Page 31: ...in the respective Project Planning Manual must be provided with pressurized media such as compressed air hydraulic oil cooling fluid and cooling lubricant supplied by external systems Incorrect handli...

Page 32: ...3 12 Safety Instructions for Electric Drives and Controls ECODRIVE03 Drive Controllers Notes customerservice hyperdynesystems com 479 422 0390...

Page 33: ...00 4 1 4 ECODRIVE03 DKC 040 DKC 100 DKC 200 4 1 Technical Data Dimensions Drive Controller DKC 3 040 7 FW 77 5 170 50 13 333 14 360 65 210 261 7 9 8 343 13 7 32 5 32 5 40 Fig 4 1 Drive Controller DKC...

Page 34: ...CODRIVE03 Drive Controllers Drive Controller DKC 3 100 7 FW 105 13 360 14 333 170 50 261 210 40 77 5 7 1 3 9 5 8 52 5 52 5 343 7 22 5 60 MB5034F1 FH7 Fig 4 2 Drive Controller DKC 3 100 7 FW customerse...

Page 35: ...ECODRIVE03 Drive Controllers ECODRIVE03 DKC 040 DKC 100 DKC 200 4 3 Drive Controller DKC 3 200 7 FW Fig 4 3 Drive Controller DKC 3 200 7 FW customerservice hyperdynesystems com 479 422 0390...

Page 36: ...g to the diagrams see Fig 4 4 Degree of utilization as a value dependent on ambient temperature and installation altitude If deviating ambient temperatures and higher installation altitudes occur simu...

Page 37: ...f o e e r g e d e l b a w o l l A fine dust no allowed no condensation 9 8 9 1 9 2 5 E C I 2 9 9 1 1 0 7 4 0 E D V N I D 9 2 5 0 6 N E o t g n i d r o c c a 0 2 P I n o i t c e t o r p f o e p y T Vi...

Page 38: ...f S 4 kHz I CONT1 4kHz A 13 1 32 1 Continuous current 2 for f S 4 kHz I CONT2 4kHz A 16 1 40 1 Continuous current 1 for f S 8 kHz I CONT1 8kHz A 9 1 21 1 Continuous current 2 for f S 8 kHz I CONT2 8kH...

Page 39: ...1 3 x AC 480V CZM01 3 when Ta 45 C PZWD 2 1 5 1 W k P r e w o p k a e p s u b C D ZWS see diagrams on page 4 27 DC bus peak power r e w o l b l a n r e t n i h t i w g n i l o o c n o i t c e s r e w...

Page 40: ...Continuous current 2 for f S 4 kHz I CONT2 4kHz 0 0 1 A 1 Continuous current 1 for f S 8 kHz I CONT1 8kHz 8 4 A 1 Continuous current 2 for f S 8 kHz I CONT2 8kHz 8 6 A 1 Max Output frequency at f S 4...

Page 41: ...thing choke and CZM01 3 at T a 45 C PZWD 7 2 W k P r e w o p k a e p s u b C D ZWS see diagrams on page 4 27 DC bus peak power Cooling power section and bleeder resistor with internal blower n o i t c...

Page 42: ...ZW R Softstart L L FS0218F1 FH7 A1 A2 A3 L1 L2 L3 Charging current limit Line input with bridge circuit rectifier Bleeder circuit DC bus capacitance Converter bridge circuit with output to the motor D...

Page 43: ...ZKS FS0219F1 FH7 A1 A2 A3 L1 L2 L3 Charging current limit Line input with bridge circuit rectifier Bleeder circuit with DC bus dynamic braking device DC bus capacitance Converter bridge circuit with o...

Page 44: ...FH7 A1 A2 A3 L1 L2 L3 Charging current limit Line input with bridge circuit rectifier Bleeder circuit with DC bus dynamic braking device DC bus capacitance Converter bridge circuit with output to the...

Page 45: ...page 4 16 Output current characteristic curves for servo applications max pulse duration of IEIN3 tN3Lade 2 1 s m see diagram on page 4 16 Output current characteristic curves for servo applications m...

Page 46: ...2 W DKC05 3 P N3 8 2 W DKC06 3 P N3 8 2 W DKC11 3 P N3 6 2 W DKC21 3 P N3 8 2 W DKC22 3 P N3 8 2 W Fig 4 12 Control voltage connection for DKC To be obtained by appropriate mains sections and shielded...

Page 47: ...tion Symbol Unit DKC 3 040 7 FW DKC 3 100 7 FW DKC 3 200 7 FW Input voltage U HB V depends on motor type listed in motor project planning manual Ripple content w Current consumption I HB A see also pa...

Page 48: ...times 400 ms Static profile illustrated DG0003F1 FH7 IPEAK ICONT IPEAK1 IPEAK2 4kHz ICONT1 8kHz IPEAK2 8kHz ICONT2 8kHz ICONT1 4kHz ICONT2 4kHz f 1 4 k H z f 2 8 k H z Fig 4 16 Output current charact...

Page 49: ...shold and DC bus voltage threshold value of connecting voltage decreases 0 10 20 30 40 50 60 70 80 90 0 100 200 300 400 500 600 Line input voltage U N1 in V W ZW in Ws Fig 4 17 Storable energy in the...

Page 50: ...VE03 Drive Controllers 0 50 100 150 200 250 300 350 400 450 500 0 100 200 300 400 500 600 Line input voltage U N1 in V W ZW in Ws Fig 4 19 Storable energy in the bus DKC 3 200 7 FW DKC 3 200 7 FW cust...

Page 51: ...vided into group supply with DC bus connection and group supply without DC bus connection Both supply options have their advantages for various demands See page 4 21 Selection criteria for supply opti...

Page 52: ...8 11 4 4 Central supply via DKC 3 100 0 not allowed 3 6 2 2 Group supply with DC bus connection DKC 3 040 0 not allowed 0 not allowed 12 2 1 Fig 4 20 Max number of ECODRIVE03 components on one DC bus...

Page 53: ...output X X largest possible peak bleeder output X X largest possible regenerative power X X largest possible DC bus output X X 1 least possible installation resources space wiring fuse protection X hi...

Page 54: ...d to the mains via separate contactors is not allowed Ap5109f1 fh7 Kn DKC 3 K1 3 3 3 3 BZM1 3 CZM1 3 040 100 DKC 3 200 3 3 016 Fig 4 22 Single source supply Note In addition to the illustrated connect...

Page 55: ...ZM1 3 CZM1 3 DKC 3 3 3 3 3 DKC 3 DKC 3 040 100 200 3 3 040 100 200 016 040 100 200 016 Fig 4 23 Group supply without DC bus connection Note In addition to the illustrated connections of the BZM01 3 at...

Page 56: ...C 3 040 See also page 16 5 Calculating the allowed continuous braking resistor and DC bus power Ap5110f1 fh7 DKC 3 K1 3 3 3 3 040 DKC 3 040 Fig 4 24 Group supply with DC bus connection Note In additio...

Page 57: ...r but to protect the integrated DC bus dynamic brake setup ZKS See also Fig 4 146 Block diagram interlock ZKS Mains Ap5112f1 fh7 K1 DKC 3 3 3 BZM1 3 CZM1 3 DKC 3 DKC 3 3 100 100 040 200 200 3 3 3 Fig...

Page 58: ...it DKC 3 using Central supply as an example CZW CZW FS0211f1 fh7 3 L L M Load 3 3 M 3 C K D 0 0 1 3 C K D Pm1 Pmn S N1 PZW Pm1 PV1 Pmn PVn Load S N1 1 F P 2W 1 K P m Fig 4 26 Energy circuit DKC 3 usin...

Page 59: ...t suited for drive applications if the required intermittent operating power of the unit s nominal power exceeds 50 Relationship peak to DC bus continuous power 0 0 5 1 1 5 2 2 5 0 5 10 15 20 25 30 t...

Page 60: ...No increase in the allowed continuous power rating See page 4 23 Arranging the Group supply without DC bus connection DKC 3 040 7 in Group supply with DC bus connection Further DKC 3 040 7 devices on...

Page 61: ...he Group supply without DC bus connection DKC 3 100 7 in Group supply with DC bus connection See DKC 3 100 7 in Central supply DKC 3 100 7 in Central supply Further DKC 3 7 devices on the common DC bu...

Page 62: ...p supply without DC bus connection DKC 3 200 7 in Group supply with DC bus connection See DKC 3 200 7 in Central supply DKC 3 200 7 in Central supply Further DKC 3 7 devices on the common DC bus incre...

Page 63: ...ce supply No increase in the allowed continuous power DKC 3 040 7 with CZM01 3 in Group supply without DC bus connection No increase in the allowed continuous power See page 4 23 Arranging the Group s...

Page 64: ...nging the Group supply without DC bus connection DKC 3 100 7 with CZM01 3 in Group supply with DC bus connection See DKC 3 100 7 with CZM01 3 in Central supply DKC 3 100 7 with CZM01 3 in Central supp...

Page 65: ...p supply without DC bus connection DKC 3 200 7 with CZM01 3 in Group supply with DC bus connection See DKC 3 200 7 with CZM01 3 in Central supply DKC 3 200 7 with CZM01 3 in Central supply Further DKC...

Page 66: ...moothing choke Note The allowed DC bus continuous power of a DKC is increased by adding components CZM01 3 reduces the load on the DC bus capacitor in DKCs GLD 12 improves form factor of the connected...

Page 67: ...thout DC bus connection DKC 3 200 7 with CZM01 3 and filter choke GLD12 in Group supply with DC bus connection See DKC 3 200 7 with CZM01 3 and filter choke GLD12 in Central supply DKC 3 200 7 with CZ...

Page 68: ...rce supply With single phase operation peak power in the DC bus is the same as continuous power Allowed DC bus continuous power in single phase mode at supply networks with a frequency of 50 Hz DKC 3...

Page 69: ...bus continuous power in single phase mode with 50 Hz Allowed DC bus continuous power in single phase mode with networks with a frequency of 60 Hz DKC 3 040 7 DKC 3 100 7 0 100 200 300 400 500 600 0 10...

Page 70: ...600 0 2000 4000 6000 8000 10000 12000 PZWD W U N3 V DKC 3 200 7 60 Hz without CZM DKC 3 200 7 60 Hz with CZM Fig 4 39 DC bus continuous power in single phase mode with 60 Hz Note Do not operate DKC 3...

Page 71: ...7s and DKC 3 100 7s are C UL listed High voltage test according to EN50178 Routine test with DC2100 V 1 s Insulation test according to EN50178 Routine test with DC500 V 1 s Separation between the ele...

Page 72: ...1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 H1 S1 S3 S2 Barcode Typenschild Barcode Typenschild 1 2 3 4 5 6 7 8 9 1 2 3 4 10 11121314 1516 1718 5 6 7 8 1 2 3 4 5 6 7 8 9 1 2 3 4 11121314 1516 1718 5 6 7 8 1...

Page 73: ...2 motor cable line input XS1 cable clamp shield connections complete shield motor cable holding brake motor temp monitoring XS2 cable clamp shield connections device typical interface X7 programming...

Page 74: ...r Fa5025f1 fh7 XS3 cable clamp bracket shield connection DKC 3 100 7 FW X11 interface for ZKS control DKC 3 040 7 FW XS3 X9 incremental encoder SSI emulation X10 expansion interface XS3 Fig 4 45 Conne...

Page 75: ...3 Fa5089f1 fh7 DKC 3 200 7 FW XS3 cable clamp bracket Shield connection X11 interface for ZKS control X9 incremental encoder SSI emulation X10 expansion interface Fig 4 46 Connections on top of unit f...

Page 76: ...g connection socket plug connection pin mains connection L1 L2 L3 protective coductor connection motor protective coductor connection mains 10 mm incremental encoder SSI emulation 1 2 3 4 5 6 7 8 9 10...

Page 77: ...oltage to additional DKCs Fig 4 51 Connections for control voltage Ap5139f1 fh7 X1 X1 1 2 3 4 5 6 7 8 24V 1 2 3 4 5 6 7 8 to additional devices Fig 4 52 Looping through control voltage Example for app...

Page 78: ...ns of the lines for looping through the control voltage are too small the terminals can be damaged Note Exceeding allowed control voltage generates error message 24 volt error See also firmware functi...

Page 79: ...gh Low min 16 V 0 5 V max 30 V 3 V 5 m h O k 3 3 1 e c n a t s i s e r t u p n I n o i t p i r c s e d l a n o i t c n u f e r a w m r i f e e S e m i t n o i t c a e R Fig 4 55 Inputs The drive halt...

Page 80: ...not applied if 24 volts not present at the emergency stop input when the E stop function is activated depends on parameterization see function description With an error in the drive depends on paramet...

Page 81: ...1 8 9 15 Fig 4 57 Connector X2 Type No of pins Design D SUB 15 Bushings on unit Fig 4 58 Design Cross section single wire mm Cross section multi core wire mm Cross section in AWG gauge no 0 25 0 5 Fi...

Page 82: ...trized with the DriveTop start up program AP5063F1 FH7 RxD TxD GND DTR DSR RTS CTS 3 2 7 20 6 4 5 max 15 m PC with 25 pin D SUB connector TxD RxD 0 V 3 2 4 5 7 RS485 RS485 X2 TxD RxD GND DTR DSR RTS C...

Page 83: ...9600 19200 baud The use of a centrally PC supported visualization unit Using an RS485 enables the commissioning of several DKCs with DriveTop without changing the interface cables is possible The foll...

Page 84: ...V 5V 0V 2 RS485 RS485 0V 5V 0V 1 Connect outer screen to device potential on PC side and converter side strain relief of metallic connector case 2 Connect the metallic connector case with the device p...

Page 85: ...on in AWG Gauge no 0 2 2 5 0 2 1 5 24 16 Fig 4 65 Connection cross section Digital Inputs Ref Limit Limit Cam1 MessT1 Cam2 MessT2 E Stop and clear error AP5313F1 FH7 1 3 4 5 6 7 8 9 10 11 X3 12 13 14...

Page 86: ...asurements are read using two binary input signals Switching signal dependent continuous block switching makes transition to the next block possible with the use of an external switching signal Note I...

Page 87: ...R1 C1 Qn Iout Schematics R1 20k C1 no data Fig 4 70 Output circuit Output voltage High Low min 16 V 0 5 V max Uext at X1 1 1V 1 5 V Output current I out 80 mA s n 0 0 6 t u o b a e m i t p o r d d n...

Page 88: ...special meaning for central supply whereby it supplies input U D power supply See page 4 88 UD power supply Delay time t d from applying mains voltage to the setting of the U D signal is single phase...

Page 89: ...g 4 77 Input circuit Input voltage range between E and E between E and 0 V between E and 0 V Working range 10 V 10 V 10 V max 15 V 15 V 15 V a t a d o n t n e r r u c t u p n I Input resistance for di...

Page 90: ...wed maximum cable length at X3 16 and X3 17 3 m Output voltage between A1 and 0 V between A2 and 0 V min 10 V 10 V max 10 V 10 V A m 2 x a m t n e r r u c t u p t u o R 0 5 1 e c n a t s i s e r t u p...

Page 91: ...3 G1Cos 4 0V 5 n c 6 0V 8 G1SDAO 9 G1Sin 10 G1Cos 11 0V 7 G1SCLK 12 13 0V 14 G1Sample 15 G1SDAI G1_8V Sin encoder 1 AP5130F1 FH7 device external device internal 1 designation from the first ECODRIVE g...

Page 92: ...0 Vss Evaluation AD converter 12 Bit 12 Bit z H k 5 7 y c n e u q e r f t i m i L 5 k 0 2 e c n a t s i s e r t u p n I Fig 4 86 Features of the differential input circuit See G1Sin S3 G1Sin S1 Featur...

Page 93: ...4 G1Cos S2 DSF sine 1 Vss without 120 Ohm matching resistor I C Bus increasing amplitude modulated signal G1Sin S3 G1Sin S1 G1Cos S4 G1Cos S2 Resolver increasing Fig 4 88 Signal allocation to the actu...

Page 94: ...wire mm max connectable cross section mm max Cross section in AWG gauge no 5 2 Fig 4 92 Connection cross section DC bus connection The DC bus connection connects several controllers to each other plu...

Page 95: ...s supplied do not make a connection possible then use short twisted wires to do so wire length max 2 x 1 m wire cross section min 10 mm not smaller than the cross section of the mains supply lead wire...

Page 96: ...EN 60 204 Switch frequency of 4 kHz Maximum allowed capacitance per unit length at A1 A2 A3 with regard to ground 0 5 nF m cable to cable 0 5 nF m Maximum allowed inductance per unit length an A1 A2 A...

Page 97: ...rs ECODRIVE03 DKC 040 DKC 100 DKC 200 4 65 WARNING No guarantee If third party cables are used then the guarantee is forfeited for the entire system Use Rexroth Indramat cables customerservice hyperdy...

Page 98: ...N n c Fig 4 96 Single phase mains connection device external device internal AP5303F1 FH7 X5 L1 L2 L3 L1 L2 L3 mains connection Fig 4 97 Three phase mains connection Note Mains connections should not...

Page 99: ...t 2 x 4 Bushing on connector Fig 4 99 Design Cross section single wire mm Cross section multi core wire mm Cross section in AWG Gauge no 0 2 2 5 1 5 2 5 16 12 Fig 4 100 Connection cross section CAUTIO...

Page 100: ...are in the motor power cable AP5297F1 FH7 X6 1 2 TM TM 3 4 5 6 7 8 motor temperature monitoring device external device internal Fig 4 101 Motor temperature monitoring AP5326F1 FH7 G R TM TM U R O T O...

Page 101: ...nnections control the holding brakes in the connected motors For the switching performance see function description To connect external loads note allowed contact loads AP5298F1 FH7 0V B X6 1 2 3 BR 4...

Page 102: ...e supply of the brake and the control voltage supply must also be observed in the case of a short circuit Ap5126f1 fh7 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 1 2 3 4 1 2 3 4 11121314 1516 1718 5 6 7 8 1...

Page 103: ...nd 750 V e g litz wires H07 wire routing parallel if possible twisted max inductance between 24 V source and X6 100 H equals about 2 x 75 m CAUTION Risk of damage Risk of damage by increased transitio...

Page 104: ...onnection of motor cable holding brake and temperature monitor for motors with connectors AP5125F1 FH7 3 4 1 2 AC Motor M 3 A1 A2 A3 U1 X6 5 6 TM TM BR BR U B 0V B 24V Ext 0V Ext DKC XE1 X5 7 8 0V B U...

Page 105: ...modules for unit specific firmware Ap5146f1 fh7 Programming module Firmware module Parameter module Barcode 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 H1 S1 S3 S2 Barcode H1 S1 S3 S2 0 1 2 3 4 5 6 7 8 9...

Page 106: ...address 9 10 1 91 FP5032F1 FH7 Switch S3 Switch S2 Barcode 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 H1 S1 S3 S2 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 Set drive address 91 Fig 4 109 Setting the drive...

Page 107: ...coder 2 AP5131F1 FH7 1 G2_5VSen 2 3 G2Ref 4 G2Ref 5 G2Cos 6 G2Cos 8 G2Sin 9 G2EnDatD 10 0V 11 G2EnDatClk 7 G2Sin 12 G2_5V 13 G2EnDatClk 14 0V 15 G2EnDatD encoder 2 X8 device external device internal G...

Page 108: ...er signal 1 0 0 2 Vss t i B 2 1 r e t r e v n o c D A n o i t a u l a v E z H k 0 0 2 y c n e u q e r f t i m i L R 0 2 1 e c n a t s i s e r t u p n I Resolution over a encoder cycle See the followin...

Page 109: ...ve encoder See G2Sin A G2Sin A See G2Sin A G2Sin A Returning encoder supply to amplifier so that encoder cable can be regulated and 5V are pending at the encoder independent of cable length Features o...

Page 110: ...Ref R G2Ref R sine 1Vss without absolute value e g gearwheel encoder reducing G2Sin A G2Sin A G2Cos B G2Cos B G2Ref R G2Ref R square TTL without absolute value reducing G2Sin A G2Sin A G2Cos B G2Cos B...

Page 111: ...ompensate the voltage drop the DKC can influence the encoder power source Using a voltage sensor the available voltage at the encoder is known For a given wire length and encoder current consumption a...

Page 112: ...0 5 10 15 20 25 30 35 40 45 50 0 0 05 0 1 0 15 0 2 0 25 0 3 I A L m A 0 25 mm A 0 5 mm A 1 0 mm L cable length I current A wire cross sections Fig 4 121 Without sensor connection Measuring Systems Co...

Page 113: ...l e l b a c x a m max allowed capacitance per length unit between the outputs between output and 0 V 5 nF 10 nF shielding see also Fig 4 125 Connection of incremental actual position value output and...

Page 114: ...q e r f t u p t u o x a m Overload protection Outputs may not be short circuited Danger of damage Fig 4 126 Differential outputs Note The differential outputs correspond to RS422 specs A termination...

Page 115: ...onally due to the internal signal processing the period duration and the duty cycle of the signals put out vary Therefore the following requirements of the signal filtering for UA1 and UA2 arise f 500...

Page 116: ...2 5 V 0 V max 5 V 0 5 V t i u c r i c e e s e c n a t s i s e r t u p n I 0 0 1 y c n e u q e r f e s l u P 1000 kHz Polarity protected within allowable input voltage range Fig 4 131 Differential outp...

Page 117: ...1 1 pulse T data 1 2 G23 G22 1 Tp G23 G22 G0 PFB T m tv pulse break 20 s G0 G23 m T Tp tv PFB SV0202F1 FH7 resolution for 4096 rotations resolution for 1 rotations 1 2 25 24 data pulse Tp least signif...

Page 118: ...n of connector Ap5268f1 FH7 1 2 3 4 5 6 Fig 4 133 Connector X10 Type No of pins Design Spring contact 2 x 3 Bushing on connector Fig 4 134 Design Cross section single wire mm Cross section multi core...

Page 119: ...recessive IAN IAN recessive SV5179F1 FH7 Fig 4 137 EcoX interface m 0 2 l h t g n e l s u b x a m bus terminating resistors on both ends of the bus cable 2 x 120 R 250 mW see also Project Planning Ma...

Page 120: ...8 9 10 11121314 1516 1718 Fig 4 138 Connector X11 Type No of pins Design Spring contact 2 x 9 Bushing on connector Fig 4 139 Design Cross section single wire mm Cross section multi core wire mm Cross...

Page 121: ...f1 fh7 R1 C1 Qn Iout Schematics R1 approximately 12 R C1 470 F Fig 4 142 Voltage source from X2 1 max output voltage dependent of control voltage an X1 1 DC 19 2 28 8 2 V A 1 0 C D t n e r r u c t u p...

Page 122: ...5 o t n o i t a l o s i l a i t n e t o P Polarity protected within allowed input voltage range Fig 4 144 Inputs The connections supply the ZKS input and permit potential free control of DC bus dynami...

Page 123: ...page 4 25 Arranging the Central supply and page 11 5 Control Circuits with internal DC bus dynamic brake ZKS UD power supply AP5285F1 FH7 n c n c X11 1 2 3 4 5 6 7 8 10 11 12 13 14 15 n c n c 16 18 1...

Page 124: ...r supply L1 L2 L3 mains voltage detected 1 Ap5281f1 fh7 UD Fig 4 148 Correlation of U D power supply and U D U D message See page 4 55 Digital outputs ready warning and UD Connection U D power supply...

Page 125: ...core wire mm Cross section in AWG Gauge no 5 2 0 1 Fig 4 153 Connection cross section Connection Choke DR DR AP5295F1 FH7 choke connection device external device internal X12 DR DR 1 2 Fig 4 154 Opti...

Page 126: ...cross section min 10 mm but not smaller than mains wire cross section wire routing twisted voltage resistance of single litz to ground 750 V e g litz wires H07 Note Connection bridged at delivery See...

Page 127: ...in tightening torque Nm max tightening torque Nm 0 3 5 2 Fig 4 156 Tightening torque Cross section single wire mm Max connectable cross section in mm Max cross section in AWG gauge no 5 2 Fig 4 157 Co...

Page 128: ...X3 and those for the command communication interfaces XS3 Connection for shields of cables at X9 X10 and X11 Drive controller XS1 XS2 XS3 DKC 3 040 12 18 6 15 6 15 DKC 3 100 12 35 6 15 6 15 DKC 3 200...

Page 129: ...25 13 X15 Parallel Interface female 25 pins X15 Fig 4 159 View of interface to command communications Technical description of connector Type No of pins Design D SUB 25 Bushing on the unit Fig 4 160...

Page 130: ...X15 12 13 14 15 16 17 18 19 20 21 22 23 24 25 2 device external device internal I6 I7 I8 I9 SM1 SM1 0V Q0 Q1 Q2 Q3 I5 I1 I2 I0 I3 I4 Q4 Q5 Q6 Q7 Q8 Q9 SM2 SM2 default settings Fig 4 162 Parallel inter...

Page 131: ...switching point 13 0V 0V Fig 4 164 Default allocation of I Os Note The I O allocation can be configured See firmware functional description R1 R3 R2 C1 I n Ap5183f1 fh7 Schematics R1 10k R2 3k3 R3 10...

Page 132: ...ts Pin Inputs Pin Outputs 11 SM1 Diff input 24 SM2 Diff input 12 SM1 Diff input 25 SM2 Diff input Fig 4 169 Default allocation of step motor inputs The stepper motor inputs are galvanically isolated f...

Page 133: ...og Jog The axis can be moved positively or negatively in jog mode by using the jog and jog inputs EK5030f1 fh7 Fig 4 172 Rotational direction with jog View from front of the output drive side arrow in...

Page 134: ...ingle channel control because the noise immunity of differential signals is better than zero referenced signals AP5315F1 FH7 Uext R pull up SM SM 0Vext Schematics Fig 4 173 Controlling with open colle...

Page 135: ...s tL 2 8 s t1 1 4 s turning cw t1 Fig 4 174 Stepper motor interface types of control Logic 1 is detected with a positive voltage difference of SM to SM Logic 0 is detected with a negative voltage diff...

Page 136: ...tion LED of SERCOS interface fiber optic connection for SERCOS ring switch to set data rate Fig 4 175 View of command communication interface Connection diagram for SERCOS interface DKC02 3 AP5049F1 F...

Page 137: ...rking on the unit FP5031F1 FH7 3 2 1 ON OFF S20 H20 ERROR 3 2 1 X20 X21 TX RX Switch for setting the transmitter power Switch for setting the data rate Distortion LED of the SERCOS interface Fig 4 177...

Page 138: ...IKO985 or IKO 001 are used Connection without separation If couplings are used the maximum length for plastic fiber optic cables is reduced by about 10 meter 100 meters for glass fiber optic cables F...

Page 139: ...ic ring CNC SERCOS interface fiber optic plug in connector control cabinet bushing Mat Nr 252 524 6mm 2mm IKO0985 for external control cabinet installation length in meters IKO0982 dependent on how th...

Page 140: ...ins Diagnostic indicators Fig 4 181 View of command communication interface Technical description of connector Type No of pins Design t i n u e h t n o g n i h s u B 9 B U S D Fig 4 182 Design Cross s...

Page 141: ...184 Profibus DP interface for DKC03 3 As per DIN EN 50 170 as per DIN EN 50 170 2 cable type A Pin DIR Signal Function c n 1 c n 2 3 I O RS485 receive transmit data plus 4 O CNTR P Repeater control s...

Page 142: ...t resistance 350 R VOL 0 8 V at I OL 2 mA VOH 3 5 V at I OH 1 mA Receive send data EIA RS485 standard Fig 4 186 Signal specification CAUTION Danger of destroying output 5V Repeater supply with overloa...

Page 143: ...BUS line must be set on ON Matching resistor at the beginning of the PROFIBUS line must be set to ON 1 Set matching resistor to OFF Fig 4 187 An example of connecting a DKC03 3 to the PLC control via...

Page 144: ...A B A B A B S ie m e n s on off S ie m e n s Switch connection for the first and final slave in the Profibus DP The cable shield must be placed bare on the metal guide Fig 4 189 Bus links for the fir...

Page 145: ...4 23 Bus link for the first and last slave without 9 pin D SUB socket INS 0540 Siemens Siemens Ap5077f1 fh7 1 2 1 2 A B A B A B A B Siemens on off Siemens Terminating resistor is off The cable shield...

Page 146: ...ins X40 Incoming interface male 9 pins Fig 4 193 View of command communication interface Technical description of connector Type No of pins Design t i n u e h t n o g n i h s u b 9 B U S D t i n u e h...

Page 147: ...xternal device internal outgoing Interface incoming interface Fig 4 196 InterBus Interface for DKC04 3 as per DIN EN 50 254 1 as per DIN EN 50 254 1 as per DIN EN 50 254 1 as per DIN EN 50 254 2 n o i...

Page 148: ...nterface Via D subminiature mounting screws and metal connector housing as per DIN EN 50 254 1 Incoming and outgoing interfaces must be isolated from each other and galvanically from the controller Th...

Page 149: ...CAN Open Interface male 9 pins Fig 4 199 View of command communication interface Technical description of connector Type No of pins Design t i n u e h t n o s n i p 9 B U S D Fig 4 200 Design Cross se...

Page 150: ...s l a i t n e r e f f i D L _ N A C 2 d n G V 0 3 c n c n 4 n o i t c e n n o c d l e i h S d l e i h s 5 V 0 V 0 6 l a n g i s l a i t n e r e f f i D H _ N A C 7 c n c n 8 c n c n 9 Fig 4 203 Interf...

Page 151: ...ace male 5 pins X60 5 1 Fig 4 204 View of command communication interface Technical description of connector Type No of pins Design COMBICON 5 Bushing on the connector Fig 4 205 Design Cross sections...

Page 152: ...P V 0 V 1 l a n g i s l a i t n e r e f f i D N A C 2 n o i t c e n n o c d l e i h S d l e i h s 3 l a n g i s l a i t n e r e f f i D N A C 4 y l p p u s e c a f r e t n I V 5 Fig 4 208 Interface si...

Page 153: ...FA5061F1 FH7 X210 H215 H213 H211 H214 H212 H210 37 19 20 1 Diagnostic display X210 Parallel Interface 2 male 37 pins Fig 4 210 View of command communications interface Technical description of connect...

Page 154: ...FH7 Parallel interface 2 X210 device external device internal n c n c 0V I 0 I 15 O 0 O 11 n c Fig 4 213 Parallel interface 2 for DKC21 3 The definitions of the displays are listed in the firmware fu...

Page 155: ...3 5 1 I I 6 1 c n 6 3 0 0 Q O 7 1 c n 7 3 1 0 Q O 8 1 19 O Q 02 Fig 4 214 Signal assignment of 37 pin connector X210 Via D subminiature mounting screws and metal connector housing R1 R3 R2 C1 I n Ap5...

Page 156: ...1 Hand Auto 18 Q 1 Auto 3 I 2 Start 19 Q 2 Error 4 I 3 STOP 20 Q 3 Run 5 I 4 Jog 21 Q 4 Output 01 6 I 5 Jog 22 Q 5 Output 02 7 I 6 Input 01 23 Q 6 Output 03 8 I 7 Input 02 24 Q 7 Output 04 9 I 7 Input...

Page 157: ...r SERCOS ring switch to set data rate Fig 4 220 View of command communication interface Connection diagram for SERCOS interface 2 AP5369F1 FH7 optical transmitter X220 fiber optic cable optical receiv...

Page 158: ...4 126 ECODRIVE03 DKC 040 DKC 100 DKC 200 ECODRIVE03 Drive Controllers Notes customerservice hyperdynesystems com 479 422 0390...

Page 159: ...t n o C e v i r D 3 0 E V I R D O C E 5 1 5 ECODRIVE03 DKC 3 016 5 1 Technical Data Dimensions 270 9 8 32 5 13 7 32 5 210 13 260 14 287 65 229 7 Mb5071f1 fh7 Fig 5 1 Drive Controller DKC 3 016 7 FW cu...

Page 160: ...I R D O C E 6 1 0 3 C K D 3 0 E V I R D O C E Materials used Mass Designation Symbol Unit DKC 3 016 7 FW Mass m kg 3 2 Materials used free of asbestos and silicone Fig 5 2 Materials used mass custome...

Page 161: ...6 1 0 3 C K D 3 0 E V I R D O C E s r e l l o r t n o C e v i r D 3 0 E V I R D O C E 5 3 Ambient and operating conditions See page 4 4 customerservice hyperdynesystems com 479 422 0390...

Page 162: ...NT2 4kHz A 6 1 Continuous current 1 for f S 8 kHz I CONT1 8kHz A 2 8 1 Continuous current 2 for f S 8 kHz I CONT2 8kHz A 5 1 Max output frequency at f S 4 kHz f out Hz 400 Max output frequency at f S...

Page 163: ...c r o f o n w o l f r i a g n i l o o C Volumetric capacity of the forced cooling m h no forced cooling Insulation resistance at DC500V R is 1 m h O M Coupling capacitance power section against housi...

Page 164: ...oad at control outputs and encoder interface 2 DKC01 3 P N3 5 1 W DKC02 3 P N3 5 1 W DKC03 3 P N3 6 1 W DKC04 3 P N3 7 1 W DKC05 3 P N3 6 1 W DKC06 3 P N3 6 1 W DKC21 3 P N3 6 1 W DKC22 3 P N3 6 1 W F...

Page 165: ...ng current profile of control voltage Note For n parallel switched inputs the charging current inrush is n fold Voltage connection for holding brake Designation Symbol Unit DKC 3 016 7 FW Input voltag...

Page 166: ...s acceleration times 400 ms Static profile illustrated DG0003F1 FH7 IPEAK ICONT IPEAK1 IPEAK2 4kHz ICONT1 8kHz IPEAK2 8kHz ICONT2 8kHz ICONT1 4kHz ICONT2 4kHz f 1 4 k H z f 2 8 k H z Fig 5 8 Output cu...

Page 167: ...energy that can be stored in the DC bus as the differential voltage between bleeder threshold and DC bus voltage threshold value of connecting voltage decreases 0 10 20 30 40 50 60 70 80 90 0 100 200...

Page 168: ...mains voltage is applied to the DKC drive controller via individual mains connections Arranging the single source supply Ap5401f1 fh7 K1 3 3 Fig 5 10 Single source supply Note In addition to the illus...

Page 169: ...c for the group supply is that the mains voltage is applied to groups of DKC drive controllers via a common mains contactor Arranging the single source supply Ap5405f1 fh7 K1 3 3 3 3 3 3 Fig 5 11 Grou...

Page 170: ...016 7 FWs are not suited for drive applications if the required intermittent operating power of the unit s nominal power exceeds 50 Allowed DC bus continuous power DKC 3 016 7 in Single source supply...

Page 171: ...am Note The single phase mains connection is only permitted with single source supply With single phase operation peak power in the DC bus is the same as continuous power Allowed DC bus continuous pow...

Page 172: ...ed DC bus continuous power in single phase mode at supply networks with a frequency of 60 Hz UN V P ZWD W 0 100 250 200 300 400 500 600 50 150 200 300 350 400 100 Kl0004 fh7 Fig 5 15 Allowed DC bus co...

Page 173: ...7Y4 Fig 5 17 C UL listing High voltage test according to EN50178 Routine test with DC2100V 1 s Insulation test according to EN50178 Routine test with DC500 1 s Separation between the electrical circui...

Page 174: ...ress switch X4 encoder 1 device typical interface X5 motor connection X5 mains connection XS1 holes for cable ties to fix cable shields XS2 holes for cable ties to fix cable shields XE1 protective con...

Page 175: ...V I R D O C E 5 17 Connections on top of the drive controller Fa5143f1 fh7 X3 digital in outputs X10 expansion interface XS3 holes for cable ties to fix cable shields Fig 5 20 Connections on top of un...

Page 176: ...operation digital inputs and outputs clear error protective coductor connection motor protective coductor connection mains 10 mm voltage connection for brake motor connection mains connection DKC 3 0...

Page 177: ...or power consumption X1 1 see page 5 6 Control voltage connection e g n a r e g a t l o v d e w o l l a a i V n o i t c e t o r p e g a t l o v e s r e v e R using internal protection diodes Note Stro...

Page 178: ...tor to coast torque free without brake DANGER Dangerous movements due to unbraked coasting of motor with control voltage failure Personnel should not remain within the area of the machine with moving...

Page 179: ...ge High Low min 16 V 0 5 V max 30 V 3 V 5 m h O k 3 3 1 e c n a t s i s e r t u p n I n o i t p i r c s e d e r a w m r i f l a n o i t c n u f e e S e m i t n o i t c a e R Fig 5 28 Inputs The drive...

Page 180: ...r DKC is not applied if 24 volts not present at the emergency stop input when the E stop function is activated depends on parameterization see function description With an error in the drive depends o...

Page 181: ...onnector Ap5265f1 FH7 1 8 9 15 Fig 5 30 Connector X2 Type No of pins Design D SUB 15 Bushings on unit Fig 5 31 Design Cross section single wire mm Cross section multi core wire mm Cross section in AWG...

Page 182: ...at a time can be parameterized with the DriveTop start up program AP5395f1 FH7 RxD TxD GND DTR DSR RTS CTS 3 2 7 20 6 4 5 max 15 m 1 TxD RxD 0 V 3 2 7 X2 TxD RxD GND DTR DSR RTS CTS 3 2 5 4 6 7 8 max...

Page 183: ...m Cross section in AWG Gauge no 0 2 2 5 0 2 1 5 24 16 Fig 5 37 Connection cross section Digital Inputs Ref Limit Limit Cam1 MessT1 Cam2 MessT2 E stop Clear error AP5396f1 FH7 1 3 4 5 6 7 8 X3 9 10 11...

Page 184: ...nd time measurements are read using two binary input signals Switching signal dependent continuous block switching makes transition to the next block possible with the use of an external switching sig...

Page 185: ...s Ap5184f1 fh7 R1 C1 Qn Iout Schematics R1 20k C1 no data Fig 5 42 Output circuit Output voltage High Low min 16 V 0 5 V max Uext an X1 1 1 V 1 5 V Output current I out 80 mA s n 0 0 6 t u o b a e m i...

Page 186: ...rations but would eventually lead to an error then the warning is set to high See also functional firmware description If the unit is ready for the drive enable then the output ready is set to high Th...

Page 187: ...G1Sin 3 G1Cos 4 0V 5 n c 6 0V 8 G1SDAO 9 G1Sin 10 G1Cos 11 0V 7 G1SCLK 12 13 0V 14 G1Sample 15 G1SDAI G1_8V Sin encoder 1 AP5130F1 FH7 device external device internal 1 designation from the first ECOD...

Page 188: ...signal 9 0 Vss Evaluation AD converter 12 Bit y c n e u q e r f t i m i L 5 k 8 e c n a t s i s e r t u p n I Fig 5 49 Features of the differential input circuit see G1Sin S3 G1Sin S1 Features of the...

Page 189: ...l position value with default setting amplitude modulated signal G1Sin S3 G1Sin S1 G1Cos S4 G1Cos S2 Resolver increasing Fig 5 51 Signal allocation to the actual position value Note default setting se...

Page 190: ...me time Observe the information contained in chapter 3 Safety Instructions for Electric Drives and Controls Technical description of connector Fig 5 52 Connector X5 Note To pull off the connectors loo...

Page 191: ...of 40 C per EN 60 204 Switch frequency of 4 kHz Maximum allowed capacitance per unit length at A1 A2 A3 with regard to ground 0 5 nF m cable to cable 0 5 nF m Maximum allowed inductance per unit leng...

Page 192: ...ING No guarantee If third party cables are used then the guarantee is forfeited for the entire system Use Rexroth Indramat cables Illustration of the correctly connected motor cable See page 16 19 Con...

Page 193: ...tion AP5400f1 FH7 X5 L1 L2 L3 L1 L2 L3 device external device internal Fig 5 58 Three phase mains connection Note Mains connections should not be daisy chained between the units intermediate connector...

Page 194: ...ction single wire mm Cross section multi core wire mm Cross section in AWG Gauge no 0 2 2 5 1 5 2 5 16 12 Fig 5 61 Connection cross section CAUTION Damages by exchanging the connectors X6 1 3 and X6 4...

Page 195: ...nnection leads are in the motor power cable AP5383F1 FH7 X6 1 2 TM TM 3 4 5 6 motor temperature monitoring device external device internal Fig 5 62 Motor temperature monitoring AP5326F1 FH7 G R TM TM...

Page 196: ...the vertical axes mass and the gravitational force These control the holding brakes in the connected motors For the switching performance see function description To connect external loads note allow...

Page 197: ...he motor projection Ap5385f1 fh7 X1 X6 24V to the central ground Fig 5 65 Shared voltage source for brakes and control voltage supply Note Looping through the voltages to other drive controllers is im...

Page 198: ...ee motor manual Basic connection of motor power holding brake and motor temperature monitoring AP5387F1 FH7 AC Motor M 3 U1 V1 W1 X1 X2 T1 T2 U BR BR 3 4 1 2 A1 A2 A3 X6 5 6 TM TM BR BR U B 0V B 24V E...

Page 199: ...6 1 0 3 C K D 3 0 E V I R D O C E s r e l l o r t n o C e v i r D 3 0 E V I R D O C E 5 41 X10 EcoX Expansion interface See page 4 86 customerservice hyperdynesystems com 479 422 0390...

Page 200: ...5 67 Design min tightening torque Nm max tightening torque Nm 0 3 5 2 Fig 5 68 Tightening torque Cross section single wire mm Max connectable cross section in mm Max cross section in AWG gauge no 5 2...

Page 201: ...emperature monitoring XS2 Connection for shields of cables at X1 and those for the command communication interfaces XS3 Connection for shields of cables at X3 and X10 6 15 mm for all shield connection...

Page 202: ...Key for updating firmware S2 S3 Switch for setting the drive address Two decade switches are used to set the drive address It can be set to any number between 1 and 99 Example Switch setting S3 9 val...

Page 203: ...ones Drive address 9 10 1 91 FP5032F1 FH7 Switch S3 Switch S2 Barcode 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 H1 S1 S3 S2 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 Set drive address 91 Fig 5 71 Setting...

Page 204: ...5 46 s r e l l o r t n o C e v i r D 3 0 E V I R D O C E 6 1 0 3 C K D 3 0 E V I R D O C E Notes customerservice hyperdynesystems com 479 422 0390...

Page 205: ...To increase the allowed continuous regenerative power To increase the allowed peak regenerative power For internal DC bus dynamic brake ZKS with DKC 3 040 7 FW 6 2 Technical data Dimensions Dimension...

Page 206: ...E03 Drive Controllers Materials used Mass 3 1 0 M Z B t i n U l o b m y S n o i t a n g i s e D 5 6 g k m s s a M e e r f e n o c i l i s d n a s o t s e b s a s l a i r e t a M Fig 6 2 Materials used...

Page 207: ...c d l e i f y r a t o R Device power dissipation without internal continuous bleeder power PV 2 1 W Peak bleeder power BZM P BS BZM 0 2 1 W k Continuous bleeder power BZM when Ta 45 C under max tempe...

Page 208: ...2 A max input capacitance C N3 2 1 2 2 0 F m Fig 6 4 Control voltage connection for BZM01 3 Amplitude of the BZM control voltage charging current at startup to selecting power source 0 0 5 1 1 5 2 2...

Page 209: ...50178 Routine test with DC2100V 1 s Insulation test according to EN50178 Routine test with DC500V 1 s Separation between the electrical circuits of the control and high voltage power safe separation a...

Page 210: ...01 3 ECODRIVE03 Drive Controllers 6 3 Electrical Connections BZM01 3 Front View FA5038F1 FH7 Fig 6 8 Front view Auxiliary Bleeder Module BZM01 3 S1 Reset key H1 Diagnosis green H2 Diagnosis red custom...

Page 211: ...r operation 2 5 7 24V 24V connection for control voltage 1 0V 0V 3 0V 0V 0V 4 0V 6 Bb Bb connection for control voltage to additional devices X2 1 2 3 4 5 6 7 8 10 11 12 ZKS1 0V ZKS2 9 24Vpro Load Rea...

Page 212: ...Apply switched mains power see also page 6 15 Fig 6 25 Block diagram interlock ZKS Mains Ap5322f1 fh7 BZM1 3 DKC 3 K1 3 040 100 200 3 3 Fig 6 10 DC bus and mains connection Note In addition to the ill...

Page 213: ...in AWG gauge no 0 2 2 5 0 2 1 5 24 16 Fig 6 13 Connection cross section 24V control voltage supply 24V and 0V AP5121F1 FH7 24V 24V 0V 0V X1 2 1 3 4 5 8 7 6 device external device internal connection...

Page 214: ...2 x 75 m Note Bleeder not available once control voltage fails Control voltage failure causes the running motor to coast torque free without brake See page 11 5 Control Circuits with internal DC bus d...

Page 215: ...n WARNING Damage possible if Bb contact not connected The Bb contact acknowledges auxiliary bleeder readiness to the application of power Integrating the Bb contact of the BZM01 3 as per Control Circu...

Page 216: ...Voltage source from X2 1 max output voltage dependent of control voltage at X1 1 voltage at X1 1 2V A 1 0 C D t n e r r u c t u p t u o d e w o l l a x a m m 0 1 h t g n e l d a e l d e w o l l a x a...

Page 217: ...ed input voltage range Fig 6 23 Inputs The connections supply the ZKS input and permit potential free control of DC bus dynamic brake setup via a relay contact Mains voltage at X5 DC input DC bus setu...

Page 218: ...ZKS Mains Also see page 4 25 Arranging the Central supply and page 11 5 Control Circuits with internal DC bus dynamic brake ZKS Analog Output Load AP5306F1 FH7 for example oscilloscope CH2 CH1 XS2 X2...

Page 219: ...er resistor Ready Warning AP5309F1 FH7 Warning message 0V ext Ready message X2 1 2 3 4 5 6 7 8 10 11 12 Ready Warning 9 0V Fig 6 29 Output Ready Warning Ap5184f1 fh7 R1 C1 Qn Iout Schematics R1 20k C1...

Page 220: ...age failed Clear error The clear error input supports the resetting of the unit s internal error memory AP5310F1 FH7 0V ext Clear error X2 1 2 3 4 5 6 7 8 10 11 12 ClearError 9 0V Fig 6 32 Input clear...

Page 221: ...ctor X5 Type No of pins Design Connection block 2 3 3 Screw connection for ring terminal M5 Fig 6 36 Design min tightening torque Nm max tightening torque Nm 0 3 5 2 Fig 6 37 Tightening torque Cross s...

Page 222: ...nection possible then use short twisted wires to do so wire length max 2 x 1 m wire cross section min 10 mm not smaller than the cross section of the mains supply lead wire protection With a fuse in t...

Page 223: ...3 L1 N n c Fig 6 41 Single phase mains connection device external device internal AP5303F1 FH7 X5 L1 L2 L3 L1 L2 L3 mains connection Fig 6 42 Three phase mains connection Note Mains connections should...

Page 224: ...n tightening torque Nm max tightening torque Nm 0 3 5 2 Fig 6 44 Tightening torque Cross section single wire mm Cross section multi core wire mm Max cross section in AWG gauge no 5 2 Fig 6 45 Connecti...

Page 225: ...V Fig 6 46 Diagnostic LED green H1 State Definition blinking LED W BZM 90 W MAX BZM or PBZM 90 P BD BZM or Temperature pre warning internal heatsink continuous light overload overtemperature internal...

Page 226: ...6 22 ECODRIVE03 Auxiliary Bleeder Module BZM01 3 ECODRIVE03 Drive Controllers Notes customerservice hyperdynesystems com 479 422 0390...

Page 227: ...CZM01 3 7 1 General The auxiliary capacitance module is advantageous in the following situations reducing power loss within the control cabinet storing energy in drive applications with short cycle ti...

Page 228: ...ta Dimensions Dimension sheets auxiliary capacitance module CZM01 3 210 14 333 65 32 5 32 5 261 7 7 13 9 5 343 13 8 MB5042F1 FH7 360 Fig 7 1 Dimensions of the auxiliary capacitance module CZM01 3 Also...

Page 229: ...F m Nom discharge time constant 3 4 s Storable energy of the DC bus capacitors W ZW CZM Ws See Fig 7 4 Storable energy in the DC bus for CZM01 3 Allowed input voltage at L L at X5 UZW V DC bus voltage...

Page 230: ...bel Tests CEf1 fh7 Fig 7 5 CE label High voltage test according to EN50178 Routine test with DC2100V 1 s Insulation test according to EN50178 Routine test with DC500 1 s Separation between the electri...

Page 231: ...rs ECODRIVE03 Auxiliary Capacitance Module CZM01 3 7 5 7 3 Electrical Connections of CZM01 3 Front View FA5083F1 FH7 Fig 7 7 Front view of auxiliary capacitance module CZM01 3 customerservice hyperdyn...

Page 232: ...tightening torque Nm 0 3 5 2 Fig 7 10 Tightening torque Cross section single wire mm Cross section multi core wire mm Cross section in AWG gauge no 5 2 Fig 7 11 Connection cross section device extern...

Page 233: ...e reversed Make sure polarity is correct If the DC bus rails supplied do not make a connection possible then use short twisted wires to do so wire length max 2 x 1 m wire cross section min 10 mm not s...

Page 234: ...terminals M5 Fig 7 14 Design min tightening torque Nm max tightening torque Nm 0 3 5 2 Fig 7 15 Tightening torque Cross section single wire mm Cross section multi core wire mm Max Cross section in AWG...

Page 235: ...I J H H 1 1 2 1 1 2 2 2 1 2 MB5044F1 FH7 2 1 1 Electrical connection 2 Slot in J direction Fig 8 1 Dimensions GLD 12 Ma e in mm Type mH A A B C E F H I J Maximum connection cross section Mass kg Power...

Page 236: ...8 2 s r e l l o r t n o C e v i r D 3 0 E V I R D O C E 2 1 D L G e k o h C Notes customerservice hyperdynesystems com 479 422 0390...

Page 237: ...tripping characteristics C for DC24V NTM power supplies Note Mains filters are available to comply with EMC limits For a selection of information see project planning manual Electromagnetic Compatibi...

Page 238: ...lock B L rails DIN 50 Table of dimensions A B C C C 20 mm cooling clearance Fig 9 2 Dimensional sheet DC24V NTM power supplies 9 4 Front views FA0201F1 FH7 LED green output voltage applied Potentiomet...

Page 239: ...V V 1 2 1 Fig 9 4 Front view and terminal designation of the power supplies NTM01 1 024 004 and NTM01 1 024 006 9 5 Electrical connection Note Always use the NTM together with the line filter NFE01 1...

Page 240: ...or line Power supply Fig 9 6 Connecting the sensor cables NTM01 1 024 004 and NTM01 1 024 006 9 6 Type code NTM 01 1 024 02 2 1 A 4 2 A 6 3 A DC 24 V TL0003F1 FH7 NTM 01 1 024 02 04 06 Example Output...

Page 241: ...ers for Drive Controllers Select an autotransformer suited to both the line voltage and the power requirements of the system Proceed with the selection as follows Determine the rating group using the...

Page 242: ...er Output voltage in V of the transformer 480 i 1 26 i 1 50 240 220 500 520 540 560 580 600 620 640 660 680 i 0 52 700 i 1 08 AC 200 240 V AC 480 500 V AC 480 580 V AC 570 690 V DST 240 460 DST 500 46...

Page 243: ...60 420 180 205 240 300 335 240 300 335 420 480 C 150 175 190 195 265 130 140 155 190 215 105 130 140 155 175 140 155 175 205 222 B 260 365 395 500 540 260 260 325 395 450 190 210 260 325 365 260 325 3...

Page 244: ...output voltage AC 460 V Rated input voltage AC 240 V 460 V Mounting style horizontal mounting vertical mounting Rated power in kVA 25 kVA Product group Three phase autotransformer TL0004f1 fh7 DST 25...

Page 245: ...ing Drive controllers of the ECODRIVE03 family can be protected against overvoltages By connecting them via an isolating transformer the star point of the output side and the PE connection of the powe...

Page 246: ...d machine The ready to operate message is output via a relay contact N O If the Bb contact closes then the drive is ready to receive power The contact is thus a precondition for connecting the mains c...

Page 247: ...Before switching the device on again wait at least 300 ms plus the fall delay time of the mains contactor see page 11 12 Control Circuits with E Stop Pre requisite The E stop input is available if the...

Page 248: ...X1 X3 E Stop 1 Integrating Bb contacts of more drive controllers and BZM inseries connection Bb contact DKC 3 040 100 200 7 FW X1 X1 7 X1 X1 8 DKC 3 016 7 FW X1 X1 4 X1 X1 6 2 E stop for more drive c...

Page 249: ...tors if a controlled braking with the drive controller is not possible as a result of a unit fault For a quick discharge of the DC bus Note DKC 3 016 7 FWs and DKC 3 040 7 FWs have no internal ZKS set...

Page 250: ...power of Bb contact must be noted Fig 11 3 Example of generating the DC ZKS signal Note All ZKS setups are controlled parallel on shared DC bus loop Any delay in the drop out of the main contactor al...

Page 251: ...to the following formula With multiple controllers add the individual powers k 60 2 MITTEL EFF ZWD n M P PZWD required DC bus continuous power in W MEFF rms torque in Nm nMITTEL mean speed in min 1 k...

Page 252: ...t inrush of unit in A IEinGesamt total charging current inrush in A value relevant for fusing UN1 mains input voltage R Softstart softstart resistance of unit see relevant technical data Fig 11 7 Comp...

Page 253: ...5f1 fh7 0 4 0 2 Fig 11 8 Connected load factor for DKC 3 016 7 for 3 AC 200 480 V Factor F via P ZWD for DKC 3 040 7 and DKC 3 100 7 with and without CZM 0 0 5 1 1 5 2 2 5 3 3 5 0 5 1 2 2 5 5 7 5 10 1...

Page 254: ...continuous power P ZWD in kW Factor F Factor F for 3 AC 200 480 V Fig 11 10 Connected load factor for DKC 3 200 7 Factor F via P ZWD for DKC 3 200 7 with CZM01 3 1 4 1 5 1 6 1 7 1 8 1 9 2 0 2 1 2 2 2...

Page 255: ...3 200 7 with CZM01 3 and GLD12 1 0 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 DC bus continous power P ZWD in kW Factor F Factor F for 3 AC 200 480 V Fig 1...

Page 256: ...A Siemens type in A in ms in ms 9 1 0 10 3VU1300 ML00 or 3RV1011 1JA10 10 3TF40 or 3RT1016 54 80 120 12 1 5 16 3VU1300 MM00 or 3RV1021 4AA10 16 3TF41 or 3RT1017 72 80 120 16 2 5 20 3VU1300 MM00 or 3R...

Page 257: ...increase vs PBD on page 12 8 The distances to the temperature sensitive control cabinet components such as leads and cable channels must be maintained Power dissipation Power dissipation is determine...

Page 258: ...pation in the control cabinet for each drive controller DKC 3 016 7 FW without braking resistor power with 4 kHz 0 10 20 30 40 50 60 70 80 0 1 2 3 4 5 I A Pv W PV Power dissipation I Current Sine thre...

Page 259: ...n in the control cabinet for each drive controller DKC 3 040 7 FW without braking resistor power with 4 kHz 0 40 80 120 160 200 0 2 5 5 7 5 10 12 5 I A Pv W PV Power dissipation I Current Sine thresho...

Page 260: ...tion in the control cabinet for each drive controller DKC 3 100 7 FW without braking resistor power with 4 kHz 0 40 80 120 160 200 240 280 320 360 400 440 480 0 10 20 30 I A Pv W PV Power dissipation...

Page 261: ...ipation in the control cabinet for each drive controller DKC 3 200 7 FW without braking resistor power with 4 kHz 0 100 200 300 400 500 600 700 800 900 1000 0 10 20 30 40 50 60 I A Pv W PV Power dissi...

Page 262: ...controllers on the mounting surface mounting plate of the control cabinet with all over contact Distances The power dissipation of the drive controller DKC and the auxiliary braking resistor module BZ...

Page 263: ...the area of the cooling air outlet Observe the distance d see also page 4 6 Electric Data of the Individual DKC 3 Components and page 6 3 Electrical data of auxiliary component BZM01 3 Note Diagram T...

Page 264: ...increase in K for d 160mm Temperature increase in K for d 200mm Fig 12 12 Temperature increase DKC 3 040 7 FW 0 20 40 60 80 100 120 140 160 0 125 250 400 500 Continuous bleeder power P BD in W Temper...

Page 265: ...0 200 400 600 800 1000 Continuous bleeder power P BD in W Temperature increase in K Temperature increase in K for d 80mm Temperature increase in K for d 120mm Temperature increase in K for d 160mm Te...

Page 266: ...0 0 250 500 800 1000 Continuous bleeder power P BD in W Temperature increase in K Temperature increase in K for d 80mm Temperature increase in K for d 120mm Temperature increase in K for d 160mm Tempe...

Page 267: ...ing the specified increments there is a distance of 5 mm between the units In order to observe the specified vibration fatigue limit see page 4 5 please note the following In case fastening screws are...

Page 268: ...necessary mount air guiding plates with blowers For example air baffle Additional fan Discharge direction of the warmed air in the flow off area Discharge direction of the warmed air in the flow off a...

Page 269: ...3 100 supply feed Fig 12 18 Example of arrangement of a Central feed For mounting details please see page 4 21 onward Arrange auxiliary capacitance module CZM next to drive with large DC bus continuou...

Page 270: ...e the following information Under normal conditions if a cooling unit is used then water condensation occurs Therefore note the following Always arrange cooling so that water condensation cannot drip...

Page 271: ...m temperature and no lower Cooling units with temperature must be set so that the inside temperature of cabinet is not lower than the outside temperature Set temp limit to maximum room temperature Use...

Page 272: ...f Rexroth Indramat should only be used by a Machine Manufacturer to create terminal diagrams for a facility When wiring a facility an End user should only use the diagrams of the Machine Manufacturer...

Page 273: ...le duct with metal divider Metal cable duct MB5008F1 FH7 2 4 mm 100 mm Plastic cable duct Fig 12 21 Cable duct variant Note Details are specified in the project planning manual Electromagnetic compati...

Page 274: ...12 18 s r e l l o r t n o C e v i r D 3 0 E V I R D O C E t e n i b a C l o r t n o C e h t g n i t c u r t s n o C Notes customerservice hyperdynesystems com 479 422 0390...

Page 275: ...ing ECODRIVE03 components come in separate units Rexroth Indramat takes the packaging material back free of charge The customer is charged for the return transport The barcode sticker on the packaging...

Page 276: ...dependent X 1 2 3 4 5 6 10 15 20 21 30 40 41 50 60 210 DKC01 3 7 X X X X X X DKC02 3 7 X X X X X DKC03 3 7 X X X X X DKC04 3 7 X X X X X DKC05 3 7 X X X X X X X X X X X 7 3 6 0 C K D DKC21 3 7 X X X...

Page 277: ...NE VERSORG 74 CU ISOL 277743 2 SCHR LIN M 6 0X25 0 K 8 8 ISO7045 ZN Z4 276873 BEIPACKZETTEL SUP M01 DKC 3 040 N M g n u n n e n e B k c t S DB112137 1 DOK GENERL DRIVE SVS1 MS P 271404 DB_55817 1 INS0...

Page 278: ...from a sales office of Rexroth Indramat GmbH Replacement Parts Contact protection Connecting and mounting accessories SUP M DKC 3 040 Connecting and mounting accessories SUP M DKC 3 040 Connecting an...

Page 279: ...is on this label The designation of the actual cable without connector is printed on the cable sheath The accessories in the bags are either identified with their ID on the bag or there is a packagin...

Page 280: ...4 2 Type plate 2 Unit type TS0014F1 FH7 Production week Serial number Hardware index Barcode Part number Device type Fig 14 3 Type plate DKC example Note The type plates for units BZM CZM NTM NFD NFE...

Page 281: ...S0013F1 FH7 Production week Serial number Module type Barcode Part number Change index Fig 14 5 Type plate DST DLT GmbH D 97816 Lohr a M Type Prim Sec S DST 20 S 580 480 480 580 V 380 460 V 30 25 A 20...

Page 282: ...14 4 s r e l l o r t n o C e v i r D 3 0 E V I R D O C E s t n e n o p m o C e h t g n i y f i t n e d I Notes customerservice hyperdynesystems com 479 422 0390...

Page 283: ...rations without extensive assembly and adjustments to quickly eliminate the problem and replace the defective component When returning a defective unit to Indramat Customer Service please complete the...

Page 284: ...r to the stamp on the cable sheathing Engine Feedback Cable IN 488 for instance AP5143F1 fh7 Barcode 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 H1 S1 S3 S2 Barcode Typenschild 1 2 3 4 5 6 7 8 9 1 2 3 4 1...

Page 285: ...les and terminals wait for the capacitor to discharge Only then work on the cables Remove contact protection and separate connecting line from the drive controller Release screws on top and bottom of...

Page 286: ...with an indirect path measuring systems via a motor encoder will loose the reference dimension if the motor is replaced This reference to machine coordinate system must therefore be reestablished Ser...

Page 287: ...iate environment requirements Conductive contamination cannot occur when operating the control drive at least not with the IP 65 when installing or exchanging drive components non conductive contamina...

Page 288: ...ramat representative Fault Report dated Information about the drive Data on rating plate Enter display data at time problem occurred Information about machine at which problem occurred Describe the pr...

Page 289: ...gramming module Open the programming module Ap5146f1 fh7 Programming module Firmware module Parameter module Barcode 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 H1 S1 S3 S2 Barcode H1 S1 S3 S2 0 1 2 3 4 5...

Page 290: ...the programming module Insert old parameter module into new firmware module Close lock lock must be pushed outward Insert programming module and screw on Switch drive controller on Replacing the Prog...

Page 291: ...rt DOLFI Press Button Connect Open IBF file of the fimware by pressing button Open file Transfer the three files of the IBF file by pressing button Transfer file and confirm the transfers In event of...

Page 292: ...15 10 Replacing or Exchanging Drive Components ECODRIVE03 Drive Controllers Notes customerservice hyperdynesystems com 479 422 0390...

Page 293: ...the system PZWS units allowed DC bus peak power of the units Fig 16 2 DC bus peak power Energy flux from installation to DC bus units RD system RD P P PRD system required continuous regenerative power...

Page 294: ...100A 200A PZWS BZM allowed DC bus peak power BZM PRD Ger te allowed continuous regenerative power of the units PRD DKC allowed continuous regenerative power DKC 40A 100A 200A PRD BZM allowed continuo...

Page 295: ...e system PRD Anlage resulting continuous regenerative power of the system PRS Anlage resulting peak regenerative power of the system W R Anlage resulting regenerative power of the system W ROT rotary...

Page 296: ...esistor can additionally be built in or It can be stored as energy in the DKC with connected auxiliary capacitance module and then re used for acceleration procedures This reduces the heat in the cont...

Page 297: ...continuous operation by all devices on the common DC bus in kW PBD DKC continuous braking resistor power that the drive controller can consume in continuous operation in kW PBD BZM continuous braking...

Page 298: ...for 3 DKC02 3 040 drive controllers ID 3 x 3 3 N N U P 3 x V W 24 19 2 31 A Fig 16 12 Continuous current I D IE 3 x I EIN3 3 x 4 A 12 A Fig 16 13 Charging current I E Duration of the charging current...

Page 299: ...p for shielded motor power cable connected over large surface l Strain relief for motor power and feedback cables EB0005F1 FH7 5 Cable channel power supply air evacuation duct 4 A A min 400 1 min requ...

Page 300: ...directly to the strain relief track on the control cabinet leadthrough of the motor power cable 6 Distance c see page 12 6 Distances Sectional Drawing for Developing an Optimum Control Cabinet The dep...

Page 301: ...e v i r D 3 0 E V I R D O C E 16 9 Mounting the cooling unit onto top Sectin A A DKC 3 Top mounted cooling unit control cabinet door EB0007F1 FH7 Fig 16 16 Mounting the cooling unit onto top customer...

Page 302: ...0 E V I R D O C E t n e m h c a t t A 16 4 Wire routing and wiring of the drive controller DKC 3 016 control connections View of DKC02 3 016 Fa5149x1 jpg Fig 16 17 View with SERCOS interface customers...

Page 303: ...n e m h c a t t A s r e l l o r t n o C e v i r D 3 0 E V I R D O C E 16 11 View of DKC03 3 016 Fa5148x1 jpg Fig 16 18 View with Profibus DP Interface customerservice hyperdynesystems com 479 422 039...

Page 304: ...6 12 s r e l l o r t n o C e v i r D 3 0 E V I R D O C E t n e m h c a t t A View of DKC21 3 016 Fa5147x1 jpg Fig 16 19 View with Parallel Interface 2 customerservice hyperdynesystems com 479 422 0390...

Page 305: ...ion FA5150x1 jpg Fig 16 20 Detail view X1 X3 X10 XS2 and XS3 Fasten the cable shields with 2 cable ties each at XS2 or XS3 Control connection DKC 3 040 100 200 l Note Representing all DKC 3 drive cont...

Page 306: ...4 s r e l l o r t n o C e v i r D 3 0 E V I R D O C E t n e m h c a t t A View with contact protection FA5104X1 jpg Fig 16 21 View with contact protection customerservice hyperdynesystems com 479 422...

Page 307: ...t n e m h c a t t A s r e l l o r t n o C e v i r D 3 0 E V I R D O C E 16 15 View of DKC02 3 040 7 FA5105X1 jpg Fig 16 22 View with SERCOS interface customerservice hyperdynesystems com 479 422 0390...

Page 308: ...16 s r e l l o r t n o C e v i r D 3 0 E V I R D O C E t n e m h c a t t A View of DKC03 3 040 7 FA5106X1 jpg Fig 16 23 View with Profibus DP Interface customerservice hyperdynesystems com 479 422 03...

Page 309: ...n e m h c a t t A s r e l l o r t n o C e v i r D 3 0 E V I R D O C E 16 17 View of DKC21 3 040 7 FA5107X1 jpg Fig 16 24 View with Parallel Interface 2 customerservice hyperdynesystems com 479 422 039...

Page 310: ...a t t A Detail view X4 X8 and XS2 with cable shield connection FA5109X1 jpg Fig 16 25 Detail view X4 X8 XS2 Detail view X9 X10 X11 and XS3 with cable shield connection FA5108X1 jpg Fig 16 26 Detail v...

Page 311: ...with two cable ties to the shield connection at the heatsink Fasten the motor cable and the mains cable in the control cabinet as near as possible to the drive controller because the two cable ties do...

Page 312: ...D O C E t n e m h c a t t A View with contact protection DKC 3 040 7 FA5110X1 jpg Fig 16 28 View with contact protection Note SUP E01 DKC 3 as of hardware index A65 is integrated in device DKC 3 040 7...

Page 313: ...e l l o r t n o C e v i r D 3 0 E V I R D O C E 16 21 View X5 X6 XE1 XE2 and XS1 with cable shield connection on DKC 3 040 7 FA5111X1 jpg Fig 16 29 View X5 X6 XE1 XE2 and XS1 customerservice hyperdyne...

Page 314: ...e l l o r t n o C e v i r D 3 0 E V I R D O C E t n e m h c a t t A View with contact protection DKC 3 100 7 FA5112X1 jpg Fig 16 30 View with contact protection customerservice hyperdynesystems com 47...

Page 315: ...e l l o r t n o C e v i r D 3 0 E V I R D O C E 16 23 View X5 X6 XE1 XE2 and XS1 with cable shield connection on DKC 3 100 7 FA5113X1 jpg Fig 16 31 View X5 X6 XE1 XE2 and XS1 customerservice hyperdyne...

Page 316: ...n DKC 3 200 7 FA5114X1 jpg Fig 16 32 View with contact protection Note Two bridges may be cut off to simplify the seating of the contact protection when using circular cross sections 16 mm FA5118X1 ti...

Page 317: ...r t n o C e v i r D 3 0 E V I R D O C E 16 25 View X5 X6 X12 XE1 XE2 and XS1 with cable shield connection on DKC 3 200 7 FA5115X1 jpg Fig 16 34 View X5 X6 X12 X100 XE1 XE2 and XS1 customerservice hyp...

Page 318: ...l o r t n o C e v i r D 3 0 E V I R D O C E t n e m h c a t t A RS485 Connector Fig 16 35 Connecting the RS485 Connectors Fig 16 36 Connecting the RS485 Connectors customerservice hyperdynesystems com...

Page 319: ...needed to record signal paths when commissioning a prototype The PC is needed to program parameterize and diagnose when starting up and servicing Hardware requirements IBM compatible min 80486 micropr...

Page 320: ...command value box circuit recommendation 12 10k V 13k DC 10 10 V 15 V 15 V analog E1 1 2 3 4 24V RF 0VM AP5096F1 FH7 X3 X1 DKC Command value box Reverse direction command value 13 14 15 analog E1 anal...

Page 321: ...ied Motor brake released AH takes effect internally for synchronous motors Fig 16 38 Recommended switching on sequence t1 Depends on functions and configuration t2 Made up of Slow operation of mains c...

Page 322: ...l output at X3 not for DKC 3 016 RF applied Signal drive enable applied by user Actual brake contact Brake contact in DKC 3 on X6 is triggered Brake contact parameterized as N C or N O see firmware fu...

Page 323: ...drive torque free K1 contactor dropped out line voltage at X5 cleared Ud message Fig 16 39 Recommended off sequence t1 Brake time of drive Maximum value parameterizable see firmware functional descri...

Page 324: ...tact see firmware functional description Brake closed brake connected via brake contact is closed Contactor K1 removed Mains contactor at X5 removed start DC bus dynamic brake discharge UD Signal Sign...

Page 325: ...machinery Safety related parts of control systems Part 1 General principles for design EN 1037 1995 12 Safety of machinery Preventation of unexpected start up EN 12415 1996 05 Machine tools Safety Sm...

Page 326: ...icherheit von Maschinen Sicherheitsbezogene Teile von Steuerungen Teil 1 Allgemeine Gestaltungsleits tze DIN EN 1037 1996 04 Sicherheit von Maschinen Vermeidung von unerwartetem Anlauf DIN EN 12415 19...

Page 327: ...ew of Drive Controllers and Auxiliary Components 1 3 An Overview of Individual Components of the ECODRIVE03 Family 1 2 Analog inputs 4 57 Analog inputs 1 and 2 4 57 Analog Interface 4 121 Analog outpu...

Page 328: ...3 X30 4 108 X4 4 59 X40 4 114 X41 4 114 X5 4 62 X50 4 117 X6 4 67 X60 4 119 X8 4 75 X9 4 81 Connection diagram for DeviceNet Interface 4 120 Connection diagram for InterBus Interface 4 115 Connection...

Page 329: ...e 2 4 122 Diagnostic display for Profibus DP Interface 4 110 Diagnostic LEDs and Reset Probe BZM 6 21 Differential signals 4 103 Digital I Os DKC 3 016 5 25 Digital outputs ready and warning message D...

Page 330: ...ns 4 40 designations DKC 3 016 5 16 Drive enable 4 47 5 21 Drive halt 4 47 5 21 Drive halt AH and Drive enable RF 4 47 Drive halt AH and Drive enable RF DKC 3 016 5 21 Drive package ECODRIVE03 1 1 DST...

Page 331: ...Holding brake BR BR 4 69 Holding brake DKC 3 016 5 38 Holding brakes 4 67 Holding brakes DKC 3 016 5 36 Homing switch 4 54 I Identifying the Components 14 1 Inappropriate use 2 2 Consequences Dischar...

Page 332: ...68 Motor temperature monitoring TM TM DKC 3 016 5 37 Mounting Accessories 13 4 mounting plate 12 6 Mounting Position 12 6 Mounting the cooling unit onto top 16 9 Multiple Row Construction of the Contr...

Page 333: ...016 7 FW 15 9 Firmware DKC 3 040 100 200 7 FW 15 7 Firmware Module 15 8 Motor 15 4 Parameter Module 15 7 Programming Module 15 8 Replacing the Motor 15 4 Resettaster DKC 3 016 5 44 RS232 interface 4...

Page 334: ...e energy 7 4 Storable energy in the bus 4 17 Storable energy in the bus DKC 3 016 5 9 Switch S2 S3 4 74 Switch S2 S3 DKC 3 016 5 45 Switch S20 data rate transmitter power 4 105 Switch S22 4 125 T Tech...

Page 335: ...kes 4 70 Voltage connection for brakes DKC 3 016 5 39 Voltage connection for holding brake 4 15 Voltage connection for holding brake DKC 3 016 5 7 W Wall cooling unit in the control cabinet door 16 8...

Page 336: ...X8 Encoder 2 4 75 X9 Incremental and Absolute Encoder Emulation SSI format 4 81 XE1 4 95 XE1 DKC 3 016 5 42 XE1 XE2 DKC 3 016 5 42 XE2 4 95 XE2 DKC 3 016 5 42 XS1 6 20 XS1 DKC 3 016 5 43 XS1 Shield C...

Page 337: ...zuerst Kontakt mit unserem f r Sie n chstgelegenen Ansprechpartner auf http www indramat de de kontakt adressen Die Angaben in der vorliegenden Dokumentation k nnen seit Drucklegung berholt sein At ww...

Page 338: ...st Germany South West Bosch 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 6...

Page 339: ...aolo Veronesi 250 10148 Torino Tel 39 011 224 88 11 Fax 39 011 224 88 30 Italy Italien Bosch Rexroth S p A Via del Progresso 16 Zona Ind 35020 Padova Tel 39 049 8 70 13 70 Fax 39 049 8 70 13 77 Italy...

Page 340: ...38 18 42 Poland Polen Bosch Rexroth Sp zo o Biuro Poznan ul Dabrowskiego 81 85 60 529 Poznan Tel 48 061 847 64 62 63 Fax 48 061 847 64 02 Rumania Rum nien Bosch Rexroth Sp zo o Str Drobety nr 4 10 app...

Page 341: ...61 46 22 Fax 91 0 22 7 68 15 31 India Indien Bosch Rexroth India Ltd Rexroth Indramat Division Plot 96 Phase III Peenya Industrial Area Bangalore 560058 Tel 91 0 80 8 39 73 74 Fax 91 0 80 8 39 43 45 r...

Page 342: ...Tel 1 905 335 55 11 Fax 1 905 335 41 84 michael moro boschrexroth ca Canada West Kanada West Bosch Rexroth Canada Corporation 5345 Goring St Burnaby British Columbia Canada V7J 1R1 Tel 1 604 205 5777...

Page 343: ......

Page 344: ...Printed in Germany 2 8 0 1 0 7...

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