Mannesmann Rexroth DKR02 Manual técnico

DKR02, DKR03 and DKR04

Drive Controllers

Project Planning Manual

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

mannesmann

Rexroth

engineering

Indramat

Rexroth

SYSTEM200

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

About this Documentation DKR Drive Controllers

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

DKR02, DKR03 and DKR04 Drive Controllers

Project Planning Manual

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

•Document Number: 120-0700-B326-02/EN

This document serves the purpose of:

•planning the mechanics of the control cabinet,

•planning the electrical connections,

•determining the available accessories required,

•integrating the mechanical parts into the control cabinet,

•generating the installation guidelines of the machine manufacturer and

•identifying the machines and the components.

Description Release

Date Notes

209-0042-4130-00 July 95 1st edition

DOK-DIAX03-DKR********-PRJ1-EN-P Aug. 96 DKR04 included, doc. code

added

DOK-DIAX03-DKR********-PR02-EN-P 10.00 The DKR05 devices are

described in a separate

documentation.

2000 Rexroth Indramat GmbH

Copying this document, giving it to others and the use or communication

of the contents thereof without express authority, are forbidden. Offenders

are liable for the payment of damages. All rights are reserved in the event

of the grant of a patent or the registration of a utility model or design

(DIN 34-1).

All rights are reserved with respect to the content of this documentation

and the availability of the product.

Rexroth Indramat GmbH

Bgm.-Dr.-Nebel-Str. 2 •D-97816 Lohr a. Main

Telephone +49 (0) 93 52/40-0 •Tx 689421 •Fax +49 (0) 93 52/40-48 85

http://www.rexroth.com/indramat

Dept. ECD (SA/VS/BB)

This document has been printed on chlorine-free bleached paper.

Title

Type of Documentation

Document Typecode

Internal File Reference

Purpose of Documentation

Record of Revisions

Validity

Published by

Note

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

DKR Drive Controllers About this Documentation

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

Note: The following documentation is not required in its entirety for

the correct use of the drive controllers DKR.

Title Type of

Documentation Document Typecode Part

Number

AC Drive Units in Hazardous Areas

(Expl. Protection) Instructions for

Use DOK-GENERL-ANTR*EXPLOS-ANxx-EN-P 266 304

AC Drive Units in Personnel Conveyor

Systems Instructions for

Use DOK-GENERL-ANTR*PERSON-Anxx-EN-P 266 305

Electromagnetic Compatibility (EMC)

in Drive and Control Systems Project Planning

Manual DOK-GENERL-EMV********-PRJ*-EN-P 259 814

DIAX03/04, ECODRIVE03

AC-Hauptantriebe mit 2AD- und ADF-

Motoren /

AC main drives with 2AD- and ADF-

motors

Auswahldaten /

Selection data DOK-DRIVE*-MAIN*WZM***-AU01-MS-P 289 233

DIAX03 Plug-in modules for digital

intelligent drive controllers Project Planning

Manual DOK-DIAX03-PLUG*IN*MOD-PRxx-EN-P 275 155

DIAX03 AC Drives for Continuous

Operation (S1) Selection data DOK-DIAX03-PRIN******-AUxx-EN-P 274 660

DIAX03/04, ECODRIVE03

AC-Hauptantriebe für Dauerbetrieb

(S1) /

AC-Drives for Continuous Operation

(S1)

Auswahldaten /

Selection lists DOK-DRIVE*-PRINT******-AUxx-MS-P 288 730

Asynchronous Linear Motors LAF Selection Data

DIAX03 / DIAX04 DOK-MOTOR*-LAF********-AUxx-EN-P 277 353

DIAX03 ... Drive

configuration DOK-DIAX03-xxxxxxxxx**-INxx-EN-P ⊕1

Indramat Internal Connection System

LWL - Handling Application

Description DOK-CONNEC-CABLE*LWL**-AWxx-EN-E 284 755

⊕1: You need this document in order to determine the drive configuration or

to specify the hardware configuration labelling of a DIAX03 drive

controller. It is part of a firmware box set.

x: The "x" is a replacement character.

Fig.: Supplementary documentation

Supplementary documentation

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

About this Documentation DKR Drive Controllers

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

Note: The following list may not be absolutely complete. The author

reserves the right to make changes to this list as needed.

Where? What?

Supplementary documentation included

General Safety Guidelines update

Appropriate use added

Record of Revisions added

introduction of devices reorganized

Entire document new layout

conversion of cooling method included

brake resistor DZB included

Entire document data regarding other units than the ones described in this documentation replaced by

cross references (cables, motors, plug-in modules)

Sales & Service Facilities included

Chapter “Service and checks” information on how to replace units and fault report included

Electrical connections serial interface included

Mains connection power circuit-breaker added

Cooling system noise test data included

Technical data revision

Fig.: Changes with regard to the previous version

DOK-DIAX03-DKR********-PRJ1-EN-P

Changes from previous version

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

DKR Drive Controllers Contents I

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

Contents

1 Important directions for use 1-1

1.1 Appropriate use..............................................................................................................................1-1

Introduction ..............................................................................................................................1-1

Areas of use and application....................................................................................................1-2

1.2 Inappropriate use...........................................................................................................................1-2

2 Safety instructions for electric servo drives and controls 2-1

2.1 Introduction.....................................................................................................................................2-1

2.2 Explanations...................................................................................................................................2-1

2.3 Hazards by inappropriate use........................................................................................................2-2

2.4 General information........................................................................................................................2-3

2.5 Protection against contact with electrical parts..............................................................................2-4

2.6 Protection by protective low voltage (PELV) against electrical shock ...........................................2-6

2.7 Protection against dangerous movements.....................................................................................2-6

2.8 Protection against magnetic and electromagnetic fields during operations and mounting............2-8

2.9 Protection against contact with hot parts .......................................................................................2-9

2.10 Protection during handling and installation....................................................................................2-9

2.11 Battery safety...............................................................................................................................2-10

2.12 Protection against pressurized systems ......................................................................................2-10

3 Introducing the devices 3-1

3.1 Drive controllers.............................................................................................................................3-1

General features......................................................................................................................3-1

3.2 Brake resistor.................................................................................................................................3-5

4 Technical data 4-1

4.1 DKR02............................................................................................................................................4-1

4.2 DKR03............................................................................................................................................4-2

4.3 DKR04............................................................................................................................................4-4

4.4 DZB01............................................................................................................................................4-5

5 Planning the cabinet 5-1

5.1 Ambient conditions.........................................................................................................................5-1

5.2 Cooling method..............................................................................................................................5-2

Determine energy dissipation ..................................................................................................5-2

Possible cooling method variants ............................................................................................5-4

Use of cooling units..................................................................................................................5-7

5.3 Dimension sheets...........................................................................................................................5-9

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II Contents DKR Drive Controllers

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

Required distances for cooling with air from inside the cabinet...............................................5-9

DKR02....................................................................................................................................5-10

DKR03....................................................................................................................................5-12

DKR04....................................................................................................................................5-14

DZB01....................................................................................................................................5-16

5.4 Additional dimensions when cooling with a duct..........................................................................5-17

5.5 Leads............................................................................................................................................5-20

5.6 Measures to avoid sources of interference in the control cabinet................................................5-22

6 Planning the electrical connections 6-1

6.1 Preliminary remark.........................................................................................................................6-1

6.2 Fundamental guidelines.................................................................................................................6-1

6.3 Positions of the connectors, pin configurations and lead cross sections.......................................6-2

6.4 Mains connection...........................................................................................................................6-4

Grounded three-phase systems ..............................................................................................6-4

Ungrounded three-phase system ............................................................................................6-5

6.5 Dimensioning .................................................................................................................................6-9

Mains fuses and lead cross sections.......................................................................................6-9

Autotransformers ...................................................................................................................6-11

Isolating transformers ............................................................................................................6-12

Overvoltage suppressor.........................................................................................................6-13

6.6 Functions and allocations of individual interfaces........................................................................6-14

X2: Serial interface.................................................................................................................6-14

X3: Analog output and signal contact....................................................................................6-16

X4: Motor feedback................................................................................................................6-17

X6: Monitoring motor temperature and holding brakes .........................................................6-18

X7: Signal outputs..................................................................................................................6-19

X8: Signal voltages................................................................................................................6-20

X9: Control inputs for internal power contactors....................................................................6-21

X5 and X10: Power voltage, control voltage and brake resistor connections .......................6-21

7 Accessories 7-1

7.1 Connector kits................................................................................................................................7-1

Connector kit for the basic unit ................................................................................................7-1

Connector kit for all plug-in modules of a configuration including the feedback connections.7-2

7.2 Fiber optic cables...........................................................................................................................7-3

7.3 Mechanical accessories.................................................................................................................7-4

Accessories for duct cooling....................................................................................................7-4

Mounting frames......................................................................................................................7-4

8 Transport and storage 8-1

8.1 Transport........................................................................................................................................8-1

8.2 Storage...........................................................................................................................................8-1

9 Identifying the merchandise 9-1

9.1 General...........................................................................................................................................9-1

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

DKR Drive Controllers Contents III

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

9.2 Delivery slip and barcode sticker ...................................................................................................9-1

9.3 Rating plate and type code of the drive controller .........................................................................9-2

9.4 Type code of the auxiliary bleeders ...............................................................................................9-4

10 Mounting and installation 10-1

10.1 Adapting the cooling method........................................................................................................10-1

DKR02 and DKR03................................................................................................................10-1

DKR04....................................................................................................................................10-3

10.2 Mounting the drive........................................................................................................................10-6

10.3 Drive wiring...................................................................................................................................10-9

Power connector with double cable.....................................................................................10-10

11 Service and checks 11-1

11.1 Error diagnoses............................................................................................................................11-1

11.2 Repairing and replacing units ......................................................................................................11-2

11.3 Fault report...................................................................................................................................11-4

12 Index 12-1

13 Service & Support 13-1

13.1 Helpdesk ......................................................................................................................................13-1

13.2 Service-Hotline.............................................................................................................................13-1

13.3 Internet – World wide web............................................................................................................13-1

13.4 Vor der Kontaktaufnahme... - ...before contacting us..................................................................13-1

13.5 Kundenbetreuungsstellen - Sales & Service Facilities ................................................................13-2

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

IV Contents DKR Drive Controllers

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

Notes

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DKR Drive Controllers Important directions for use 1-1

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

1 Important directions for use

1.1 Appropriate use

Introduction

Rexroth Indramat products represent state-of-the-art developments and

manufacturing. They are tested prior to delivery to ensure operating safety

and reliability.

The products may only be used in the manner that is defined as

appropriate. If they are used in an inappropriate manner, then situations

can develop that may lead to property damage or injury to personnel.

Note: Rexroth Indramat, as manufacturer, is not liable for any

damages resulting from inappropriate use. In such cases, the

guarantee 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 the pre-

requisites for an appropriate use of the products are satisfied:

•Personnel that in any way, shape or form uses our products must first

read and understand the relevant safety instructions and be familiar

with appropriate use.

•If the product takes the form of hardware, then they must remain in

their original state, in other words, no structural changes are

permitted. It is not permitted to decompile software products or alter

source codes.

•Do not mount damaged or faulty products or use them in operation.

•Make sure that the products have been installed in the manner

described in the relevant documentation.

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

1-2 Important directions for use DKR Drive Controllers

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

Areas of use and application

Drive controllers made by Rexroth Indramat are designed to control

electrical motors and monitor their operation.

Control and monitoring of the motors may require additional sensors and

actors.

Note: The drive controllers may only be used with the accessories

and parts specified in this document. If a component has not

been specifically named, then it may not be either mounted or

connected. The same applies to cables and lines.

Operation is only permitted in the specified configurations and

combinations of components using the software and firmware

as specified in the relevant function descriptions.

Every drive controller has to be parameterized while starting it up, making

it possible for the motor to execute the specific functions of an application.

To ensure an application-specific use, the drive controllers are available

with differing drive power and different interfaces.

Typical applications of DKR drive controllers are:

•printing machines and

•NC machine tools.

The drive controllers may only be operated under the assembly,

installation and ambient conditions as described here (temperature,

system of protection, humidity, EMC requirements, etc.) and in the

position specified.

1.2 Inappropriate use

Using the drive controllers outside of the above-referenced areas of

application or under operating conditions other than described in the

document and the technical data specified is defined as “inappropriate

use".

Drive controllers may not be used if

•they are subject to operating conditions that do not meet the above

specified ambient conditions. This includes, for example, operation

under water, in the case of extreme temperature fluctuations or

extremely high maximum temperatures or if

•Rexroth Indramat has not specifically released them for that intended

purpose. Please note the specifications outlined in the general safety

instructions!

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

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