Mannesmann Rexroth Indramat ECODRIVE DKC01.1, Indramat ECODRIVE DKC11.1 Project Planning Manual

engineering

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mannesmann

Rexroth

ECODRIVE

DKC01.1/DKC11.1 Drive Controllers

Project Planning Manual

DOK-ECODRV-DKC01/11.1*-PRJ3-EN-P

270950

Indramat

About this documentation ECODRIVE DKC01.1/DKC11.1 Drive Controllers

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Title

Type of document

Document code

Internal file reference

Editing sequence

ECODRIVE DKC01.1/DKC11.1 Drive Controllers

Project Planning

DOK-ECODRV-DKC01/11.1*-PRJ3-EN-P

•

209-0069-4390-03

Document identification of

Date Remark

previous editions

209-0069-4390-00 EN/05.96
209-0069-4390-01 EN/06.96
DOK-ECODRV-DKC01/11.1*-PRJ1-EN-P
DOK-ECODRV-DKC01/11.1*-PRJ1-EN-P
DOK-ECODRV-DKC01/11.1*-PRJ3-EN-P

May 96
June 96
July 96
May 97
Feb. 98

First edition
Revision
2nd edition
2nd Revision
new edition

Copyright



INDRAMAT GmbH, 1996

The reproduction and transm ission of this document, the use and c om­munication of its content to thir d parties without the expr essed c onsent of
INDRAMAT GmbH are forbidden. Violators are liable for the payment of
damages. All rights are reserved in the event a patent is gr anted or a util­ity model is registered (DIN 34-1).

Publisher

INDRAMAT GmbH • Bgm.-Dr.-Nebel-Str. 2 • D-97816 Lohr a. Main
Telephone [phone] • Telex 689421 • Fax [phone]
Dept. ENA (VS, HE)

Validity

The contents of this documentation and the availability of the product are
subject to change.

DOK-ECODRV-DKC01/11.1*-PRJ3-EN-P

ECODRIVE DKC01.1/DKC11.1 Drive Controllers About this documentation

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What is this

documentation for?

Supplementary documentation

It supplies information on:

•

planning the mechanical control cabinet

•

planning the electrical system in the control cabinet

•

logistic handling of the equipment

•

preparing the resources for start-up

"ECODRIVE DKC Servo Drives with MKD"

- Selection Lists ­DOK-ECODRV-DKC+MKD****-AUS1-EN-P
for selecting the motor controller combination.

"MKD Digital AC Motors"

- Project Planning Manual ­DOK-MOTOR*-MKD********-PRJ2-EN-P
for a detailed description of the ser vomotors and for the selec tion of the

required cable.

"ECODRIVE DKC01.1/DKC11.1 Drive Controllers"

- Description of Functions ­DOK-ECODRV-DKC01/11.1-FKB1-EN-P
for testing and selecting the functions.

"EMC in Drive and Control Systems"

- Project Planning ­209-0049-4305-02 EN/04.96
for the EMC-compliant planning and installation of the drive system ( EMC

= Electromagnetic Compatibility).

DOK-ECODRV-DKC01/11.1*-PRJ3-EN-P

About this documentation ECODRIVE DKC01.1/DKC11.1 Drive Controllers

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Notes

DOK-ECODRV-DKC01/11.1*-PRJ3-EN-P

ECODRIVE DKC01.1/DKC11.1 Drive Controllers Table of contents I

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Table of contents

1 Introduction to the system 1-1

1.1 Application features..............................................................................................................................1-1

1.2 Overview of the functions.....................................................................................................................1-1

2 Safety instructions for electrical drives 2-1

2.1 General ................................................................................................................................................ 2-1

2.2 Protection against contact with electrical parts....................................................................................2-2

2.3 Protection agains t shock s caused by safety extra-low voltage (SELV)......................................... 2-3

2.4 Protection against dangerous movements........................................................................................... 2-4

2.5 Protection against magnetic and electromagnetic fields during operation and assembly ................... 2-6

2.6 Protection during handling and assembly............................................................................................2-7

2.7 Safe battery usage............................................................................................................................... 2-7

3 Selecting the components 3-1

3.1 Overview of the required components.................................................................................................3-1

3.2 Selection procedure.............................................................................................................................3-2

3.3 Compiling the required data................................................................................................................. 3-3

4 ECODRIVE DKC drive controllers 4-1

4.1 Hardware..............................................................................................................................................4-1

View of unit....................................................................................................................................4-1

Dimensional sheets and installation dimensions...........................................................................4-2

Technical data............................................................................................................................... 4-4

Type code and rating plate............................................................................................................ 4-7

4.2 Firmware..............................................................................................................................................4-8

4.3 An overview of the electrical connections............................................................................................4-9

Front view with supply terminals................................................................................................... 4-9

Overall connection diagrams....................................................................................................... 4-10

4.4 Electrical connection to the supply terminal strips.............................................................................4-14

Serial interface X1....................................................................................................................... 4-14

X2 positioning or stepper interface.............................................................................................. 4-18

X3 analog inputs and outputs...................................................................................................... 4-25

X4 terminals for the control circuit............................................................................................... 4-29

X5, X6, X7 motor connections ....................................................................................................4-30

X9 DC bus connection ................................................................................................................4-30

DOK-ECODRV-DKC01/11.1*-PRJ3-EN-P

II Table of contents ECODRIVE DKC01.1/DKC11.1 Drive Controllers

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5 BZM auxiliary bleeder module 5-1

5.1 Dimensioning the components relevant for regeneration ....................................................................5-1

5.2 Dimensional data and installation dimensions.....................................................................................5-5

5.3 Technical data......................................................................................................................................5-6

5.4 Front view.............................................................................................................................................5-6

5.5 Electrical connections.......................................................................................................................... 5-7

5.6 Type code and rating plate...................................................................................................................5-7

6 CZM Auxiliary Capacitance Module 6-1

6.1 Dimensioning ....................................................................................................................................... 6-1

6.2 Dimensional data and installation dimensions.....................................................................................6-3

6.3 Front view.............................................................................................................................................6-4

6.4 Electrical connection............................................................................................................................6-4

6.5 Type code and rating plate...................................................................................................................6-5

7 DC24V NTM power supplies 7-1

7.1 Application recommendations.............................................................................................................. 7-1

7.2 Technical data......................................................................................................................................7-1

7.3 Dimensional data and installation dimensions.....................................................................................7-2

7.4 Front views...........................................................................................................................................7-2

7.5 Electrical connection............................................................................................................................7-3

7.6 Type code ............................................................................................................................................ 7-4

8 NFD / NFE line filter 8-1

8.1 Selection .............................................................................................................................................. 8-1

8.2 Dimensional data and installation dimensions.....................................................................................8-2

8.3 Electrical connection............................................................................................................................8-3

8.4 Line filters for DC24V NTM power supplies.........................................................................................8-5

8.5 Type code ............................................................................................................................................ 8-5

9 DST / DLT transformers 9-1

9.1 Selection .............................................................................................................................................. 9-1

9.2 Autotransformers for DKC**.*-040-7-FW............................................................................................. 9-1

9.3 Autotransformers for DKC**.*-030-3-FW............................................................................................. 9-4

9.4 Electrical connection of the DKC via transformer ................................................................................9-6

9.5 Type code ............................................................................................................................................ 9-7

10 Planning the control cabinet 10-1

10.1 Notes on installing the control cabinet.............................................................................................10-1

Power dissipation........................................................................................................................10-1

10.2 Using heat-exchange units in the control cabinets ..........................................................................10-2

DOK-ECODRV-DKC01/11.1*-PRJ3-EN-P

ECODRIVE DKC01.1/DKC11.1 Drive Controllers Table of contents III

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11 Power connection 11-1

11.1 Direct power connection...................................................................................................................11-1

11.2 Line contactor/fuse protector ...........................................................................................................11-2

Calculating the phase current at the power connection..............................................................11-2

Selecting fuse protector Q1 and line contactor K1...................................................................... 11-3

11.3 Control circuit to the power connection............................................................................................ 11-4

11.4 Protection against indirect contact...................................................................................................11-5

12 Preparing for Startup 12-1

Required equipment.................................................................................................................... 12-1

13 Condition of the drive components on delivery 13-1

Packaging ...................................................................................................................................13-1

Accompanying documents..........................................................................................................13-1

Identification of the components .................................................................................................13-1

14 Index 14-1

DOK-ECODRV-DKC01/11.1*-PRJ3-EN-P

IV Table of contents ECODRIVE DKC01.1/DKC11.1 Drive Controllers

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Notes

DOK-ECODRV-DKC01/11.1*-PRJ3-EN-P

ECODRIVE DKC01.1/DKC11.1 Drive Controllers Introduction to the system 1-1

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1 Introduction to the system

1.1 Application features

The drive system with the ECODRIVE drive controllers is the most c ost­effective solution off ering the highest functionality for almost any field of
application in which translatory or rotary motions are to be automated.

Outstanding performanc e data, an ex tensive r ange of f unc tions as well as
an excellent price-to-performance ratio represent the salient features of
this drive system.

Product features in terms of the technical applications are:

•

universal implementation

•

lower total costs

•

digital drive concept

•

highly dynamic operation

•

cost-effective direct connection to the power connection

•

software travel limit switch

•

absolute or incremental position detection

•

absolute or incremental position output

•

integrated holding brake control

•

increased operating safety

•

adjustable error response

•

automatic parameter matching

•

easy startup operation

1.2 Overview of the functions

The functions of the digital, intelligent drive system are dif ferentiated pri­marily according to the interface of the higher -level control. The fields of
application for the ECODRIVE drive controllers vary accordingly.

The drive controller DKC01.1 is used as a:

•

servodrive with integrated position control

•

servodrive with analog speed interface and integrated actual position
detection

•

servodrive with stepper interface.

•

servodrive with electronic gearbox function

The drive controller DKC11.1 repr esents a partic ularly cost-eff ective solu­tion. It is used as a:

• servodrive with analog speed interface and integrated actual position
detection

DOK-ECODRV-DKC01/11.1*-PRJ3-EN-P

1-2 Introduction to the system ECODRIVE DKC01.1/DKC11.1 Drive Controllers

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Servodrive with integrated position control

SPS-Control

I/O _ card

Selection
of the
positioning
records

Control inputs

Status outputs

Actual
position
value

MS-DOS - PC

Parameters
Diagnosis
Operating data

RS 232

RS 485

Stored
positioning
records

2° position 1

1

position 2

2

2

.

2
.

4

position 32

2

®

Drive processor

DKC01.1Drive controller

with POSITIONING-interface

Fine interpolation

Position control

Speed control
Field-orinted

stator current
control

High-resolution
positioning interface

AC-servo motor

MKD

M

~

3

~

~

FS0200.fh5

Fig. 1-1: Servodrive with integrated position control

•

Up to 32 positioning blocks can be stored in the drive controller and
selected over parallel inputs. The positioning block is executed
autonomously.

•

Mechanical translatory elements such as gear ratios or f eed constants
are adapted in the drive.

•

All position, speed, and acceleration data can be weighted independ­ently of the axis kinematics.

•

A drive-internal referencing pr ocedure is available for cr eating a refer­ence dimension.

•

The axis can be moved with the jog function during setup operation.

•

The positioning speed can be influenced via the feedrate override.

•

Travel limit switch inputs and axis limit values which can be parame­terized are available for limiting the travel range.

• The drive status can be detected via status outputs.

DOK-ECODRV-DKC01/11.1*-PRJ3-EN-P

ECODRIVE DKC01.1/DKC11.1 Drive Controllers Introduction to the system 1-3

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Servodrive with analog speed interface and integrated actual
position detection

Control unit

with position control

Parameters
Diagnosis

Operating data

Position

command

value

+W

-X

Positioning

interface

AC servo motor

MKD

MS-DOS - PC

Parameters
Diagnosis

Operating data

RS 232

DKC01.1 or DKC11.1 drive
controller with ANALOG interface

®

RS 485

Drive processor

M

3

Speed
command
value

K

v

DA

analog

A

D

± 10V

Speed control
Field-oriented

stator current
control

Actual

position

High-resolution

positioning interface

value

~

~

~

Linear scale

FS0201.fh5

Fig. 1-2: Servodrive with analog speed interface and integrated actual position

detection

•

The analog speed command value can be set to any value.

•

The actual position value is output either incrementally or absolutely.

•

Using a switching input, the drive can be shut down independent of the
command value and stopped free of drift during active control.

DOK-ECODRV-DKC01/11.1*-PRJ3-EN-P

1-4 Introduction to the system ECODRIVE DKC01.1/DKC11.1 Drive Controllers

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Servodrive with stepper interface

Control unit

with step pulse generation

Interpolation

Step pulse

generation

forwards

backwards

Actual
position
value

MS-DOS - PC

Parameters
Diagnosis

Operating data

RS 232

®

RS 485

Stepper

interface

DKC01.1 drive controller
with STEPPER interface

Drive processor

Fine interpolation

Position control

Speed control

Field-oriented
stator current
control

High-resolution

position interface

AC servo motor

MKD

M

3

~

~

~

FS0202.fh5

Fig. 1-3: Servodrive with stepper interface

•

The number of steps per rotor rotation can be set to any value be­tween 16 and 65536.

•

The maximum step frequency is independent of the load. It is techni­cally impossible to "skip" steps due to the position controlled operation.

•

The stepper interface can be set to three standard signal definitions for
exchanging signals between the control and the drive controller.

- quadrature signals

- forwards/backwards signals

- step and direction signal

•

A drive-internal referencing pr ocedure is available for cr eating a refer­ence dimension.

•

The axis can be moved with the jog function during setup operation.

•

The referencing and jog speed can be influenced via the feedrate
override.

• Travel limit switch inputs and axis limit values which can be parame­terized are available for limiting the travel range.

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ECODRIVE DKC01.1/DKC11.1 Drive Controllers Introduction to the system 1-5

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Servodrive with electronic gearbox function

Lead axis
transmitter

Lead axis
position

MS-DOS - PC

Parameters
Diagnosis
Operating data

RS 232

Step motor
interface

®

RS 485

Servodrive DKC01.1

with electronic gearbox function

Drive processor

electronic gearbox

Position control
Speed control

Field-oriented
stator current
control

High-resolution
position interface

AC-Servomotor

MKD

M

3~

~

~

FS0203.fh5

Fig. 1-4: Servodrive with electronic gearbox function

•

Operating modes

Speed synchronization
Angle synchronization

•

The lead axis position is given in degrees (360 degrees repres ent one
lead axis encoder revolution)

•

The lead axis encoder must be connected to the DKC stepper inter­face.

The maximum allowable signal frequency f
limits the number of lines Z

which can be emulated.

l

on the stepper interface

max

DOK-ECODRV-DKC01/11.1*-PRJ3-EN-P

1-6 Introduction to the system ECODRIVE DKC01.1/DKC11.1 Drive Controllers

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Notes

DOK-ECODRV-DKC01/11.1*-PRJ3-EN-P

ECODRIVE DKC01.1/DKC11.1 Drive Controllers Safety instructions for electrical drives 2-1

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2 Safety instructions for electrical drives

Please read the following instructions carefully before initial startup.
These safety instructions must be observed at all times.

If the product is transferred to a third-party, the safety instructions must be
included.

Improper use of this equipment and non-compliance
with the safety instructions provided can result in
damage, personal injury or, in extreme cases, death.

WARNING

2.1 General

INDRAMAT GmbH is not liable for any damages resulting from failure
to observe the safety instructions in this document.

•

Documentation in the relevant national language should be obtained
before initial startup if the language in this doc umentation is not per­fectly understood.

•

Proper transport, correct s torage, ass em bly, and installation as well as
care in operation and maintenance are prer equisites for optimum and
safe operation of this equipment.

•

Qualified personnel:
Only qualified personnel should be permitted to operate this equipment

or work in its imm ediate vicinity. Personnel is considered qualified if it
has sufficient knowledge of the ass embly, installation, and operation of
the product as well as all warnings and precautionar y meas ures in this
documentation.

Furthermore, personnel should be trained, instructed or author ized to
switch electrical circuits on and off and to ground and m ark them in
accordance with the requirements of safety engineering. Personnel
should possess adequate safety equipment and be trained in first aid.

•

Use only replacement parts approved by the manufacturer.

•

All safety regulations and requirements for the specific application
must be followed.

•

The equipment is designed to be ins talled in mac hines for com merc ial
use.

•

Startup is only permitted once it is sure that the machine in which the
products are installed com plies with the requirements of the national
safety regulations and safety specifications of the application.
European countries: EC Directive 89/392/EEC (Machine Guideline)

• Operation is only permitted if the national EMC regulations f or the s pe­cific application have been met. European countries: EC Directive
89/336/EEC (EMC Guideline)

The instructions for installation in accordanc e with EMC requirements
can be found in the document "EMC Drive and Control Systems."

The responsibility for adherence to the lim iting values required by na­tional regulations lies with the manufacturer of the equipm ent or ma­chine.

DOK-ECODRV-DKC01/11.1*-PRJ3-EN-P

2-2 Safety instructions for electrical drives ECODRIVE DKC01.1/DKC11.1 Drive Controllers

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•

Technical specif ications as well as the connection and installation re ­quirements can be found in the produc t documentation and must be
observed under all circumstances.

2.2 Protection against contact with electrical parts

Note: Only relevant for devices and drive components with voltages ex-

ceeding 50 volts.

Coming into contact with components carrying voltages greater than 50
volts can be dangerous. Certain parts are under dangerous voltage when
operating electrical devices.

High Voltage!

Danger to life or risk of bodily injury!

⇒

Follow general construction and safety regulations

DANGER

when working on electrical installations.

⇒

Before switching on power, be sure that the ground
wire is permanently connected to all electrical units
according to the connection diagram.

⇒

At no time may electrical equipment be operated if the
ground wire is not permanently connected to the
proper terminals, even for brief measurements or
tests.

⇒

Disconnect the equipment from the power supply line
or the voltage source before beginning work. Secure
equipment from reclosure.

⇒

Wait 5 m inutes after switching off power to allow ca­pacitors to discharge before using the equipment.
Measure the voltage of the capacitors before begin­ning work in order to eliminate dangers arising from
touching components.

⇒

Never touch the electrical connection points of a com ­ponent while the power is turned on.

⇒

Cover live parts properly before switching the equip­ment on so they cannot be touched. Covers provided
with the equipment must be installed bef ore operating
the equipment to prevent contact with live parts . The
equipment may only be operated with the covers de­signed for shock-hazard protection.

⇒

A GFCI protective device (ground fault circuit inter­rupter) cannot be used for AC drives! Protection
against indirect contact must be ensured by other
means, for exam ple, by using an overcurrent protec­tion device in accordance with relevant standards.
European countries: in accordance with EN
50178/1994, section 5.3.2.3

⇒ For installation equipment protection against indirect

contact must be ensured using an external housing,
such as a control cabinet. European countries : in ac­cordance with EN 50178/1994, section 5.3.2.3

DOK-ECODRV-DKC01/11.1*-PRJ3-EN-P

ECODRIVE DKC01.1/DKC11.1 Drive Controllers Safety instructions for electrical drives 2-3

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High discharge current!

Danger to life or risk of bodily injury!

⇒

All units and the motors m ust first be connected to a

WARNING

grounding point with the ground wire or must be
grounded themselves before switching on power.

⇒

The discharge current is greater than 3.5 mA. A per­manent connection to the power supply line is there­fore required for all units. European countries (EN
50178/1994, section 5.3.2.3)

⇒

Before startup operation always connect the protec­tive conductor or the ground conductor. Otherwise the
housing may harbor high voltages.

2.3 Protection against shocks caused by safety extra-low voltage (SELV)

All connectors and terminals on INDRAMAT products with voltages from
5 to 50 volts are safety extra-low voltages offering a shock proof design to
meet the following standards:

•

international: IEC 364-4-411.1.5

•

European countries in the EC: EN 50178/1994, section 5.2.8.1

WARNING

High electrical voltages due to incorrect connec­tions!

Danger to life or risk of bodily injury!

⇒

Only equipment and lines carrying protective extra low
voltage (PELV) may be connected to connectors and
terminals with voltages ranging from 0 to 50 volts.

⇒

Connect only voltages and circuits safely isolated from
dangerous voltages. Isolation can be achieved, for
example, by using safe isolation transformers, opto­couplers or power supply independent battery opera­tion.

DOK-ECODRV-DKC01/11.1*-PRJ3-EN-P

2-4 Safety instructions for electrical drives ECODRIVE DKC01.1/DKC11.1 Drive Controllers

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2.4 Protection against dangerous movements

Dangerous movements can be caused if the connected motors are not
controlled correctly.

There are various causes of dangerous movements:

•

faulty wiring or cable connections

•

operating the components improperly

•

defective measured value transmitters and primary detectors

•

defective components

•

errors in the software

These errors can occur just after the equipm ent has been switched on or
after an indefinite period of time.

The monitors in the dr ive components virtually exclude failur e in the con­nected drives. However, personnel safety requires that additional meas­ures be taken to ensure corr ect operation. Faulty drive motions which are
influenced by the type of control and the operating status cannot be en­tirely excluded until the installed monitors take effect.

DOK-ECODRV-DKC01/11.1*-PRJ3-EN-P

ECODRIVE DKC01.1/DKC11.1 Drive Controllers Safety instructions for electrical drives 2-5

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Dangerous movements!

Danger may result in equipment damage, personal injury
or death!

⇒

DANGER

Personal safety must be ensured by higher-level,
monitoring at the installation or precautionary meas­ures for the reasons listed above. T hese are provided
by the plant manufacturer according to the specific
conditions of the plant based on a danger and mal­function analysis. The safety regulations in effect for
the plant are included herein.

Avoiding accidents:

⇒

Stay away from the machine’s movem ent area. Pos­sible measures to be taken to prevent access by un­authorized persons:

- protective fence

- protective railing

- protective covering

- light barrier

⇒

Fences and coverings should be strong enough to
withstand the maximum possible momentum.

⇒

Mount the emergency stop switch (E-stop) at an easily
accessible place in the imm ediate vicinity. Verify that
the E-stop switch works before starting operation.

⇒

Isolate the drive power connection by means of an E­stop circuit or use a starting lock-out to prevent unin­tentional startup.

⇒

Make sure that the drives have been shut down be­fore accessing or entering the danger zone.

⇒

Disable electrical power to the equipment using a
master switch and secure against reclosure during:

- maintenance and repair work

- equipment cleaning

- long downtime periods

⇒

Avoid operating high-frequency, remote control, and
radio equipment near electrical equipment and their
supply leads. If the use of such equipment cannot be
avoided, verify that the system and plant are in perfect
working order in all working situations before initial
operation. If necessary, the plant must undergo spe­cial EMC testing.

DOK-ECODRV-DKC01/11.1*-PRJ3-EN-P

2-6 Safety instructions for electrical drives ECODRIVE DKC01.1/DKC11.1 Drive Controllers

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2.5 Protection against magnetic and electromagnetic fields during operation and assembly

Magnetic and electromagnetic f ields near cur rent- c arr ying conductors and
permanent magnets pos e a serious health hazard for persons with pace­makers, metal implants and hearing aids.

Health hazard for persons with pacemakers, metal
implants and hearing aids in the immediate vicinity
of electrical equipment.

⇒

WARNING

Persons with pacemakers and metal implants must
not be permitted access to the following areas:

−

Areas in which electrical equipm ent and parts are
mounted, operated or put into operation.

−

Areas in which motor parts with permanent mag­nets are stored, repaired or mounted.

⇒

If it becomes necessary for a person with a pace­maker to enter suc h an area, this must be approved
by a physician beforehand.

Implanted pacemak ers or those to be im planted have
a varying degrees of resistance to interference, mak­ing it impossible to establish any general guidelines.

⇒

Persons with metal implants or m etal splitters as well
as hearing aids should consult a physician before en­tering such areas since they represent a health haz­ard.

DOK-ECODRV-DKC01/11.1*-PRJ3-EN-P

ECODRIVE DKC01.1/DKC11.1 Drive Controllers Safety instructions for electrical drives 2-7

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2.6 Protection during handling and assembly

Handling or assembling drive components improperly may lead to per­sonal injury.

Risk of injury due to improper handling!

Bodily injury may be caused by crushing, shearing, cut­ting, and pounding forces.

⇒

CAUTION

Observe general construction and safety regulations
when working on electrical installations.

⇒

Use suitable assembly and transport equipment.

⇒

Take precautions to prevent pinching and crushing.

⇒

Use only suitable tools. Use special tools as pre­scribed.

⇒

Employ lifting devices and tools according to the
manufacturers’ instructions.

⇒

If necessary, use suitable protective equipment (for
example goggles, safety shoes, protective gloves).

⇒

Do not stand under suspended loads.

⇒

Remove any leaking liquids on the floor immediately
to prevent slipping.

2.7 Safe battery usage

Batteries consist of reactive chemicals contained in a solid case. Im­proper use can therefore lead to injuries or equipment damage.

CAUTION

Note: Environmental protection and disposal! The batteries con-

Risk of injury due to improper handling!

⇒

Do not attempt to reactivate em pty batteries by heat­ing them or by any other means (danger of explosion
or corrosion).

⇒

Do not recharge batteries because they may leak or
explode.

⇒

Do not dispose of batteries by throwing them into a
fire.

⇒

Do not attempt to disassemble batteries.

⇒

Do not damage the electrical com ponents installed in
the equipment.

tained in the product are considered hazardous material for
land, sea, and air transport according to the legal regulations
(danger of explosion). Dispose used batteries separately from
other waste. Observe the national regulations in the country of
installation.

DOK-ECODRV-DKC01/11.1*-PRJ3-EN-P

2-8 Safety instructions for electrical drives ECODRIVE DKC01.1/DKC11.1 Drive Controllers

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Notes

DOK-ECODRV-DKC01/11.1*-PRJ3-EN-P

ECODRIVE DKC01.1/DKC11.1 Drive Controllers Selecting the components 3-1

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3 Selecting the components

3.1 Overview of the required components

System voltage

Mains filter for

power supply unit

Power supply unit

Firmware

Drive Top

commissioning

program

NFE

NTM

FWA

PC

DC 24 V

NFD

DST

Q1

K1

DKC

MKD

Mains filter for
power connections

Transformer

Fuse

Mains contactor

Drive controller

BZM CZM

IKS - ready-made feedback cable
IKG - ready-made power cable

Servo motor

Auxiliary bleeder module

Auxiliary capacitance
module

Those components shown with a gray-shaded background are absolutely necessary.

Fig. 3-1: Overview of the required components

EB0202D4.fh5

DOK-ECODRV-DKC01/11.1*-PRJ3-EN-P

3-2 Selecting the components ECODRIVE DKC01.1/DKC11.1 Drive Controllers

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3.2 Selection procedure

Dimensioning and selecting the

servo drive

Compiling the required data

Selecting the required

components

Determining components which

may be additionally required

⇒

Dimension the drive according to how it is to be used. A document f or
this is under preparation.

⇒

Select motor/drive combination (DKC + MKD) using the "Selection
Data" documentation (see pg. 3, supplementary documentation)."

⇒

Enter the values obtained from dim ensioning and enter the drives se­lected into table Fig. 3-2 .

⇒

Calculate the continuous regenerative power according to the specifi­cations in Chapter 5 and enter them in table Fig. 3-2 .

⇒

Use firmware "FW A-ECODRV-ASE-02VRS-MS" for DKC01.1-*** and
DKC11.1-*** (no selection required at this time)

⇒

"Select ready-made cables for the connection between the DKC and
MKD by using the document "MKD Servomotors - Project Planning
Manual" (see pg. 3 of supplementary documentation)."

⇒

Select fuse protector Q1 (see Chapter 11.2).

⇒

Select line contactor K1 (see Chapter 11.2).

⇒

Check the rated line voltage.

•

If, in the case of the DKC**.*-040-7, the rated line voltage f alls below
or exceeds 3xAC (380-460)V ±10%, select a DST transfor mer (see
Chap. 9.2).

•

If, in the case of the DKC**.*-030-3, the rated line voltage f alls below
or exceeds 3xAC230V ±10%, select a DST transfor mer (see Chap.

9.3).

⇒

Check the DC24V control voltage supply for the DKC. If a voltage of
DC24 Volt ± 20 % is not available, select a suitable NTM power supply
(see Chap. 7).

⇒

Check the DC24V voltage for the m otor holding brake. If a voltage of
DC24 Volt ± 10 % is not available, then select a s uitable NTM power
supply (see Chap. 7).

⇒

Check the continuous regenerative power. If it exc eeds 0.15 kW , then
consider option with BZM auxiliary bleeder module (see Chap. 5).

⇒

Check the peak regenerative power. If it exceeds 5 k W , then consider
option with DKC**.*-040-7 and if needed, the BZM auxiliary bleeder
module (see chapter 5).

⇒

If the continuous regenerative power exceeds appr ox. 0.1 kW and the
drive system energy content is less than 200W, the use of an auxiliary
capacitance module CZM can be econom ical. This mak es it possible
to reduce the dissipated energy for the control cabinet by an amount
equal to the continuous regenerative power (see Chap. 6).

⇒ Check the EMC conditions. INDRAMAT recomm ends the use of NFD

or NFE mains filters to maintain EMC limiting values (see Chap. 8).

DOK-ECODRV-DKC01/11.1*-PRJ3-EN-P

ECODRIVE DKC01.1/DKC11.1 Drive Controllers Selecting the components 3-3

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3.3 Compiling the required data

Designation Symbol Values/Units

Effective load torque

Acceleration torque

Operating torque

Motor speed used

Load moment of inertia

Maximum rotary energy in the
mechanical system (E-stop case)

Continuous regenerative power

Continuous torque at standstill

Maximum torque

Short-term operation torque

Maximum motor speed

Required power connection ou­put

Required mains rated voltage

Motor/controller combination

M

M

M

n

J

W

P

M

M

M

n

S

U

EFF

ACC

BEARB

NUTZ

LAST

RD

DN

MAX

KB

MAX

AN

N

.............................. in Nm

.............................. in Nm

.............................. in Nm

.............................. in min-1

.............................. in kgm²

ROT,MAX

.............................. in Ws

.............................. in kW

.............................. in Nm

............................. in Nm

............................. in Nm

............................. in min-1

............................. in kVA

............................. in V

DKC...................................

Motor moment of inertia

DKC current consumption

Power consumption of the motor

J

I

N,DC

I

N,HB

M

holding brake (if present)
refer to the project planning

manual MKD Motors

Fig. 3-2: Data required for selecting the components

MKD...................................

............................. in kgm²

0.7 in A

............................. in A

DOK-ECODRV-DKC01/11.1*-PRJ3-EN-P

3-4 Selecting the components ECODRIVE DKC01.1/DKC11.1 Drive Controllers

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Notes

DOK-ECODRV-DKC01/11.1*-PRJ3-EN-P

ECODRIVE DKC01.1/DKC11.1 Drive Controllers ECODRIVE DKC drive controllers 4-1

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4 ECODRIVE DKC drive controllers

4.1 Hardware

View of unit

DKC**.*-030-3-FW

(I

= 30 A)

Typ

Mains connection
1 x AC 230 V
oder
3 x AC 230 V

DKC**.*-040-7-FW

(I

= 40 A)

Typ

Mains connection
AC (380...460) V

Intermediate circuit connection
for
BZM auxiliary bleeder module
or
CZM auxiliary capacitance module
or
further DKCs

Fig. 4-1: Main distinguishing hardware features of the DKC controllers

PI0200.fh5

DOK-ECODRV-DKC01/11.1*-PRJ3-EN-P

4-2 ECODRIVE DKC drive controllers ECODRIVE DKC01.1/DKC11.1 Drive Controllers

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Dimensional sheets and installation dimensions

distance to adjacent unit

70

210

cooling air outlet

min. 80 mm

25

360

8

343

32,5

7

X1

X2

X3
X4

65

M6 in mounting panel

258

X6

S1

X5

H1

X7

X8

318

17

7

cooling air inlet

min. 80 mm

MB0201.fh5

Fig. 4-2: Dimensional data and installation dimensions DKC01.1-030-3-FW

DOK-ECODRV-DKC01/11.1*-PRJ3-EN-P

ECODRIVE DKC01.1/DKC11.1 Drive Controllers ECODRIVE DKC drive controllers 4-3

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distance to adjacent unit

70

210

cooling air outlet

min. 80 mm

8

32.5
7

65

M6 in mounting panel

258

cooling air inlet

13

333

14

min. 80 mm

360

X1
X2

X3

X4

X5

343

H1

S1

X6

X7

X8

X9

7

MB0202.fh5

Fig. 4-3: Dimensional data and installation dimensions DKC01.1-040-7-

FW/DKC11.1-040-7-FW

DOK-ECODRV-DKC01/11.1*-PRJ3-EN-P

4-4 ECODRIVE DKC drive controllers ECODRIVE DKC01.1/DKC11.1 Drive Controllers

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Technical data

Power connection / Power section

Designation

Symbol

Unit

Operating mode at the mains
Mains input voltage

Maximum conn. voltage
Making current

Mains frequency
Switching frequency (selectable)

= 4 kHz

Continous current at
Continous current at

f

S

= 8 kHz

f

S

Rated current
Peak current
Power disspation, without

bleeder dissipation

Peak bleeder output DKC

Continous bleeder output DKC

Maximum feedback energy DKC

Storage energy DKC

DC bus capacitance

DC bus voltage

1) The drive data for 4 and 8 kHz switching. frequencies are listed in the document "ECODRIVE DKC servo drive" - Selection Data.

2) Value dependent on power input voltage

2)

U

N

S

MAX

I

EIN

f

N

f

S

1)

I

CONT

1)

I

CONT

I

TYP

I

PEAK

P

V

P

BM,DKC

P

BD,DKC

W
W

C

DKC

U

ZW

MAX,DKC

ZW,DKC

V

kVA
A
Hz
kHz
A

A
A

A

W

kW
kW
kWs
Ws
mF
V

DKC01.1-030-3-FW

single-phase

1 x AC 230

three-phase

3 x AC 230

± 10%

1,8
10

4 or 8

12
11

30
30

100

5 (for 1 s)

0,15

5,0

15

0,15

not lead to the outside

± 10%

3,2

10

DKC**.1-040-7-FW

50...60

three-phase

3 x AC

(380 ... 480)

4,8 ... 9

9 ... 12

4 or 8

16

12,5

40
40

180

10 (for 0,5 s)

0,15

5,0
15

0,15

DC 500...800

± 10%

TB0202.fh5

Designation

Control voltage connection
for DKC

Input voltage
Maximum ripple content
Current consumption

Voltage connection for
holding brake

Input voltage
Maximum ripple content
Current consumption

Fig. 4-4: Technical data for the power connection and power section

DC24V Power supply

N,DC

N,HB

Unit

V
%
A

V
%

A

Symbol

U
w
I

N,DC

U
w

I

N,HB

Fig. 4-5: Technical data for the DC24V power supply

DKC01.1-030-3-FW

DKC**.1-040-7-FW

DC (19,2 ... 28,8) V

must not exceed the input voltage range

0,7

DC 24

± 10%

must not exceed the input voltage range

please see MKD dokumentation

TB0203.fh5

DOK-ECODRV-DKC01/11.1*-PRJ3-EN-P