Bosch DDC KIT Technical data

engineering
mannesmann
Rexroth
DDC 1.2
Digital Intelligent Servo Drive with Protection
Category IP 65
Project Planning Manual
DOK-DIAX02-DDC01******-PRJ1-EN-P
265092
Indramat
About this documentation
Title
Type of documentation
Document Type
Internal file reference
Reference
Purpose of the
documentation
DDC 1.2 Digital Intelligent Servo Drive with Protection Category IP 65 /
(basic unit)
Project Planning Manual
DOK-DIAX02-DDC01******-PRJ1-EN-E1,44
• Mappe 13
• DDC01-PJ.pdf
• 209-0069-4381-01
This electronic document is based on the hardcopy document with document
desig.: DOK-DIAX02-DDC01******-PRJ1-EN-P
It supplies information on:
• the electrical construction
• mounting the drive controller (basic unit)
• installing the electrical leads to the drive controller
Editing sequence
Copyright
Doc. designations of previous documents
Status
Comment
209-0069-4381-00-EN
03/95
1st edition
DOK-DIAX02-DDC01******-PRJ1-EN-P
08/96
new edition
DOK-DIAX02-DDC01******-PRJ1-EN-E1,44
01/97
1st edition of the E-Doc
© INDRAMAT GmbH, 1994
Copying this document, and giving it to others and the use or communication
of the contents thereof without express authority, are forbidden. Offenders are
liable to the payment of damages. All rights are reserved in the event of the
grant of a patent or the registration of a utility model or design (DIN 34-1).
The electronic documentation (E-doc) may be copied as often as needed if
such are to be used by the consumer for the purpose intended.
Published by
Validity
INDRAMAT GmbH • Bgm.-Dr.-Nebel-Straße 2 • 97816 Lohr, Germany
Telefon 0049-93 52 / 40-0 • Tx 689421 • Fax 0049-93 52 / 40-48 85
Dept. ENA (DE, FS)
We reserve the right to revise the contents of the documentation and to make
changes in product availability.
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
2
Table of Contents
Table of Contents
Seite
1.
Introducing the System
5
1.1.
DDC 1.2 Servo Drive ........................................................................6
1.2.
Functional Performance Features ....................................................7
1.3.
Command Interface Card .................................................................8
1.4
Software Module ..............................................................................9
1.5.
Auxiliary Plug-In Cards ....................................................................9
1.6
Configuration Rating Plate .............................................................10
2.
Technical Data / Ambient Conditions
2.1.
Data Sheet ..................................................................................... 11
2.2.
Operating Conditions .....................................................................12
3.
Electrical Connections -Installation Guidelines
3.1.
Terminal diagram ............................................................................14
3.2.
Power Connections ........................................................................15
3.3.
Grounding Conditions ....................................................................16
3.4.
Power Connection cross sections and Fuses ................................ 17
3.5.
Transformers .................................................................................. 19
3.6.
DST Three-Phase Autotransformers for Mounting in Control
Enclosures .....................................................................................20
3.7.
DLT Three-Phase Isolating Transformers for Mounting in
Control Enclosures .........................................................................21
3.8.
Three-Phase Autotransformers in IP 55 Housing ..........................22
3.9.
Motor Power Connection ...............................................................23
11
13
3.10. Motor Feedback Connection .......................................................... 27
3.11. Interface to NC Control Unit ...........................................................28
3.12. Control Circuit of the DDC Mains Contactor ..................................29
3.13. Control Circuit in the DDC with Dynamic Braking ..........................30
3.14. Control circuit of the DDC Mains Contactor Without Dynamic
Braking ........................................................................................... 32
3.15. Control Circuit of the DDC Mains Contactor with E-Stop Relays ..34
3.16. Control Inputs .................................................................................36
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
3
Table of Contents
3.17. Signal and Diagnostics Outputs .....................................................37
3.18. Signal Voltages ..............................................................................38
3.19. Reading Drive Parameters .............................................................39
3.20. Regenerated Power .......................................................................39
3.21. Fault Current Protective Device .....................................................40
3.22. High-Voltage Testing ......................................................................40
4.
Mounting the DDC 1.2
4.1.
DDC 1.2-N - dimensional data .......................................................41
4.2.
Front View of DDC 1.2-N ...............................................................42
4.3.
Power Connections ........................................................................43
4.4.
Minimum Clearances .....................................................................44
5.
Ordering Information
5.1.
Type Codes for the DDC 1.2 .......................................................... 46
5.2.
Accessories for Connections ......................................................... 47
5.3.
Item List ..........................................................................................50
6.
Index
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
41
46
51
4
1. Intrroducing the System
1.
Introducing the System
DDC 1.2 drive
controller
configured
configuration
rating plate
A1
A2
Software module
viewing window
plug-in modules
mains
Motor
power cable
interface to the machine
controller
Motor feedback
cable
AC servo
motor MDD
KBDKS1.8
Fig. 1.1: Digital AC drive with DDC drive controller
Digital AC Drive
Digital AC drives are microprocessor controlled, brushless, three-phrase
drives which are highly dynamic and have precision servo-control features.
All
• drive control,
• monitoring,
• parametrization and
• diagnostics operations
are performed digitally with a signal processor.
The drive features needed for precise servo-applications are available to the
drive because of the high-resolution rotor position measurements across the
entire speed range.
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
5
1.Introducing the System
1.1. DDC 1.2 Servo Drive
IP65 is the protection category of a DDC 1.2. It can be installed directly at the
feeder even under less favorable environmental and manufacturing conditions.
This avoids long cables susceptible to faults.
Basic unit
A DC bus converter is built into the basic unit as well as the bleeder resistor
for the energy generated during braking, a mains contactor for disconnecting
the power and a power section for the control voltages. Plug-in cards are
inserted into slots U1 through U5, depending on the application requirements.
A configured DDC is supplied by INDRAMAT as a completely assembled unit.
Drive controller
configuration
Such a servo drive is made up of the following components:
• the basic unit
• the command interface card (see section 1.3)
• the software module (see section 1.4)
• optional auxiliary plug-in modules (see section 1.5)
• the configuration rating plate (see section 1.6)
drive controller, basic unit
configuration
ratiing plate
A1
A2
software module
5
tU
slo
1
command
communications
module
tU
slo
t
slo
U2
t
slo
U3
t
slo
U4
PZDKSProj
auxiliary
plug-in module
Fig. 1.2: DDC 1 drive controller configuration
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
6
1. Introducing the System
1.2. Functional Performance Features
Protection Category IP 65:
• space-saving installation, without a control cabinet, directly at the feeder
• elimination of long connections between motor and drive which are
susceptible to interference
Power shutoff via integrated protection system in DDC:
• power supply isolated by a contactor built into the unit
• direct connection to 220V three-phase power source
• a longer lifespan due to currentless switching
Integral DC bus dynamic braking:
• If trouble is encountered in the electronic circuitry of the drive, the drive can
be decelerated and stopped with an integral dynamic brake system.
Inrush current limit:
• The inrush current does not need to be considered when selecting fuses or
circuit breakers for the input power.
Flexibility for specific applications:
• The functions implemented on the drive can be matched to the given
application by installing various plug-in modules in the servo drive.
Motor holding brake:
• Control and monitoring of the holding brake of the motor is integrated inside
the servo drive unit.
Programmable error reactions:
• In the event of power, drive, or system faults, the drive performs the
programmed error reaction.
Easy to service:
• Signal cables are connected via screw terminals.
• Extensive diagnostics via alphanumeric display.
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
7
1. Introducing the System
1.3. Command Interface Card
Depending upon type, the command interface module is either the interface
to the NC control unit or a positioning control unit with interfaces to the hand
terminal or the NC control unit of the machine.
The following command interface cards are available:
• SERCOS interface, type: DSS 1.1, DSS 1.3
• ANALOG interface with incremental encoder emulator, type: DAE 1.1
• ANALOG interface with absolute encoder emulator, type: DAA 1.1
• Positioning module, type: DLC 1.1
SERCOS interface
Type: DSS 1.1, DSS 1.3
The "SERCOS interface DSS" card allows the digital drives to be operated
with SERCOS interface-compatible controllers via optical fiber cables. The
interface also has inputs for evaluating reference switches, position limit
switches and sensors.
ANALOG interface
with incremental
encoder emulator
Type: DAE 1.1
ANALOG interface
with absolute encoder
emulator
Type: DAA 1.1
Single-axis positioning
module
The "ANALOG interface with incremental encoder emulator" card permits the
intelligent digital AC servo drive to be operated with conventional controllers
via an analog interface. It also contains control inputs and signal outputs for
communication with attached controllers, and it outputs incremental encoder
signals to be used as an actual position value.
The "ANALOG interface with absolute encoder emulator" card permits the
intelligent digital AC servo drive to be operated with conventional controllers
via an analog interface. It also contains control inputs and signal outputs for
communications with an attached controller and it outputs actual absolute
position values in accordance with SSI standards (Synchronous Serial Interface).
Type: DLC 1.1
The "single-axis positioning module" card upgrades the servo drive to perform
stand-alone, single-axis position control. This card can be programmed with
up to 3,000 program blocks. Each program block defines a sequence of
movements, a specific condition of the inputs to be monitored, or the outputs
to be set.
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
8
1. Introducing the System
1.4
Software Module
Type: DSM 2.1
Parmeters stored in the software module are used to tune the drive to the
motor and the mechanics.
Advantage when
replacing unit
The software module contains both the operating software and the parameters.
This module ensures that when hardware is replaced, the previously entered
parameters are not lost and can be carried over to the new hardware by simply
plugging in the old software module.
Duplication
Software modules can be duplicated for use in other, identical machines or for
storage purposes.
Standard software
module
The drive parameter values set by Indramat are stored in the feedback of the
MDD motors. These can be activated upon request at the time of commissioning.
The user-specific parameters are set at the machine to the machine-dependent
values.
Documentation and administration of all user parameter values is
the sole responsibility of the user.
1.5. Auxiliary Plug-In Cards
The heading "auxiliary plug-in cards" includes the following:
Type: DEA 4.1, DEA 5.1, DEA 6.1
Input/output interface
These plug-in cards each have 15 inputs and 16 outputs. The drive uses these
to exchange binary signals with a programmable controller.
The three types differ with regard to the internal address set on the card.
Incremental position
interface
Type: DEF 1.1, DEF 2.1
The auxiliary plug-in cards "incremental position interface" are used to receive
squarewave signals so that data from an external measuring system located
directly on the moving machine element can be input to the servo drive. The
cards differ according to which internal address is set on the card.
Type: DLF 1.1
High-resolution
positioning interface
The auxiliary plug-in card "high-resolution position interface" is used to
transfer sine wave signals so that data from an external measuring system
directly mounted to the moving machine elements can be input to the servo
drive.
The technical data and terminal diagrams for the plug-in cards can be
found in document "Plug-in modules for digital intelligent servo
drives". doc. no.: 209-00069-4356.
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
9
1. Introducing the System
1.6
Configuration Rating Plate
The configuration rating plate contains the type codes for:
• the configured servo drive
• the basic unit
• the software module in slot U5
• the plug-in cards in slots U1 through U4
These type codes can be used to determine which components must be
located in which slots.
In the event of malfunctions, the information on the configuration rating plate
can be used to obtain a corresponding unit or to configure a basic unit. A
replacement unit results when a basic unit is configured with the cards
identified on the configuration rating plate.
The configuration rating plate indicates which cards are installed on
the servo drive. Before commisioning the servo drive, check to be
certain that the actual configuration matches that on the configuration
rating plate.
SYSTEMCONFIGURATION
type of configured
drive controller
basic unit type
DDC 1.2-N100A-DL01-01-FW
DDC 1.2-N100A
U
1 DLC 1.1
U
2 DEA 4.1
slot designation
U
3 COVER
type of plug-in
module
U COVER
4
U FWC-DSM 2.1-C11-02V02-MS
5
configuration rating
plate type
type of software
module
TYS-DDC 1.2-N050C-DL01-00
TSDDC
COVER = there is no plug-in module in this slot
Fig. 1.3: An example of a configuration rating plate
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
10
2. Technical Data/Ambient Conditions
2.
Technical Data / Ambient Conditions
DDC 1.2-N200A
Designation
DDC 1.2-N100A
DDC 1.2-N050C
2.1. Data Sheet
Power section
3x 220 V (+15%/-10%) or
Input voltage
U(N)
(V)
3x 230 V (+10%/-15%)
f(N)
(Hz)
50 ... 60 Hz
I(peak)
(A)
50
100
200
Short-term curent for
50 % at100 s duty cycle time
I(S6-100s)
(A)
50
70
90
Continuous current (average)
I(cont)
(A)
25
35
45
f(T)
(kHz)
8
Required connected load
S(An)
(kVA)
Power requirement
with maximum drive load
S(An)
(kVA)
6
18
22.5
Short term mechanical operating P(S6-100s)
load for 50 % at100 s
duty cycle time, approx.
(kW)
8
12
15
Continuous mechanical load,
average
P(mech)
(kW)
4
6
7.5
Usable mechanical peak load,
approx.
P(mSp)
(kW)
8.5
17
33
P(V)
(W)
Continuous bleeder power
P(BD)
(kW)
0,25
0.25
0.25
Peak bleeder power
P(BM)
(kW)
10
20
40
W(max)
(kWs)
5
10
20
m
(kg)
21
22
22
Frequency
Peak current
Pulse frequency (PWM-frequency)
Power loss at maximum device
load without bleeder power loss
Maximum regenerated power
Weight of basic unit
4
Depends on motor/servo drive combination - see selection lists
500
Environmental conditions
Permissible ambient temperature
for rated specifications
Maximum ambient temperature
for derated specifications
Storage and shipping temp.
T(amb)
o
+ 5 ... + 45 oC
T(m.amb)
o
+ 55 oC
T(L)
o
- 30 ... + 85 oC
C
C
C
Maximum installation elevation
without derating
1000 meters above sea level
Permissible relative humidity
max. 95 %
Permissible absolute humidity
25 g water / m3 air
Degree of contamination
- non-conductive dirt contamination
- no condensate
Protection category
IP 65 as per EN 60 529 ( IEC 529 )
Fig. 2.1: Technical data - DDC 1.2
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
11
2. Technical Data/Ambient Conditions
2.2. Operating Conditions
Increased ambient
temperatures
The torque and power ratings listed in the selection documentation apply to an
ambient temperature range of +5° to +45° C. Maximum permissible ambient
temperature can equal up to +55° C. Otherwise, there is a drop in power as
depicted in the following figure.
Temperature factor [%]
100
80
60
40
20
ambient temperature ϑ [°C]
0
0
10
20
30
40
50
60
DGREDBELAST
Fig. 2.2: Reductoin in power data with increased ambient temperature
Installation above
1000 meters
If the unit is installed at elevations higher than 1000 meters above sea level,
then torque and power ratings will drop. The following figure depicts this drop.
reduction factor [%]
100
80
60
40
20
installation
elevation [m]
0
0
1000
2000
3000
4000
5000
DGREDLEIST
Fig. 2.3: Reduction in power data at elevations greater than 1000 meters.
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
12
3. Electrical Connections - Installation Guidelines
3.
:
Electrical Connections Installation Guidelines
The DDC 1.2 terminal diagram found in this document is a
recommendation of the manufacturer of the unit. The circuit diagrams
of the machine builder must be used for installation.
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
13
3. Electrical Connections - Installation Guidelines
3.1. Terminal diagram
ready-made
cable IKS
374
INS 513
INK 209
TM+ E
E
0VB G
G
K1
BR F
F
K1
free J
D
D
C
C
B
B
A
A
frei
X8
Digital Servo Feedback
holding
brake
H
U
X5
TM- H
Bb
PTC
INS 217
(INS 110 with
DDC 1.2-N050C)
MDD
servo motor
INS 290
UD
Q1
3 x AC; 50...60 Hz
L1
L2
L3
PE
optional interface
U4
Compact digital
drive controller
DDC 1.2
BVW
D
INS 478
10
6
5
1
8
12
3
2
4
7
9
3
acknowledge
Power OFF
wh 12
gn
bn
pk
gr
bn 12
bk
red
bl
vio
M
acknowledge
Power ON
+15VM
control
voltage
infeed
do not assign!
0VM
INS 172
(INS 108 with
DDC 1.2-N050C)
drive ready signal
-15VM
K1
power infeed
working
+24VL
X4
4
0VM
2
S9
S+
3
CC + 10
UG 12
14
FS
7
SCL
15
SDI
SDO 8
1
X7
Bleeder temperature
prewarning
0VL
power
infeed
ZKS
AK2
0VM
AK1
A
B
C
ON
power
on OFF
controls
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
0VM
DSM programming module
U5
X3
4
3
2
1
analog
diagnostics
outputs
signal voltages
for measuring
and testing
purposes
CTS
RTS
RxD
TxD
optional interface
U3
CTS
RTS
RS 232
interface RxD
TxD
0VM
optional interface
U2
X2
10
5
4
3
2
1
interface of command variables
U1
optional interface
module connections
as per relevant
terminal diagrams
APDDC11
Fig. 3.1: Terminal diagram of DDC 1.2 servo drive
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
14
3. Electrical Connections - Installation Guidelines
3.2. Power Connections
Connection voltage
Frequency
The DDC 1.2 drives can be connected to three-phase mains rated at AC 220V
(+ 15 % -10%) or AC 230V (+10 / -15%).
50 ... 60 Hz
To operate the DDC 1.2 in residential and light industrial areas, it may
be necessary to install an rf suppression filter in the mains supply
line so that the limits for the emission of interference (radio interference
suppression) are not exceeded.
Connected load
The connected load must be calculated when determining supply line diameters,
fuses and matching transformers.
SA N = M e ff · nA V · F + 0,125kVA
9550
SAN
M eff
n AV
F
F
F
0.125
= connected load in kVA
= effective motor torque in Nm
= average motor speed in min-1
= factor for motor and drive efficiency and current form
= 1.75 with a three-phase connection
= 2.1 with a single-phase connection
= power consumption of the control unit voltage source in kVA
The average motor speed for feed functions in transfer facilities is
generally no greater than 25% of the rapid traverse speed.
In some cases, it may be necessary to precisely calculate average
motor speed.
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
15
3. Electrical Connections - Installation Guidelines
3.3. Grounding Conditions
Grounded threephase
systems
With the help of an autotransformer, voltages can be adapted to three-phase
mains witch is in reference to the ground (TN or TT mains). The DDC 1 can be
directly connected to 3 x AC 220 V mains.
Ungrounded
threephase systems
There is an increased danger in ungrounded mains (IT mains) that overvoltages
will occur between the phases and the housing. The DDC 1 should only be
operated with such systems, if:
• it is connected across an isolation transformer or
• if the installation is protected with an overvoltage conductor.
Connecting the DDC 1.2 across an isolation transformer offers the
best possible protection against overvoltage and the greatest
operating safety!
Permissible
overvoltage levels
The voltage between phase connections (A, B and C) and the DDC 1.2
housing can equal 230 V (effective).
Non-periodic overvoltages as per VDE 0160 between phases and housing are
acceptable for the DDC 1.2 to the extent as shown below:
UN+∆U
UN
∆U
2.6
2.4
2.3
2.2
2
1.8
T
UN
1.6
∆U
2
3
1.4
1.2
1.15
1.1
1
0.1
0.2
0.4 0.6 1 1.3 2
4
6 10
T (ms)
20
DGUEBSPG
Fig. 3.3: Permissible non-periodic voltages as per VDE 0160
The DDC 1.2 can be connected to 3 x AC 230 V mains.
The maximum permissible non-periodic overvoltage thus equals:
230V ⋅
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
2 ⋅ 2.3 = 745V
16
3. Electrical Connections - Installation Guidelines
3.4. Power Connection cross sections and Fuses
The power connections of the DDC 1.2 can be protected with either power
circuit breakers or slow-blo gL-type fuses.
Fusing for three-phase
connections
The recommended fuse on the input side of the matching tansformer with 3 x
AC 400 V mains.
A power circuit breaker or slow-blow fuse is generally used on the input side
of a matching transformer. The use of power circuits has the advantage that
it is not possible to operate with two phases when one fuse is blowed out.
The recommended fuses and line cross sections apply if INDRAMAT
transformers are used. Make sure that the secondary lines are protected
against short circuiting, in particular, if an isolation transformer with low-power
is used.
Transf.
power in
kVA
2.0
2.5
3.5
4.0
5.0
7.5
10
12.5
15
18
20
25
Direct connection to 3
x AC 220 V mains
Rec. power circ.
Tuning
breaker1)
range
(motor circ. break.)
in A
primary second.
type Siemens
Current in A
2.9
3.6
5.1
5.8
7.2
10.8
14.5
18.1
21.7
26.0
28.9
36.1
5
6.3
8.8
10
12.6
18.8
25.1
31.4
37.7
45.2
50.3
62.8
3VU1300-.MK00
3VU1300-.ML00
3VU1300-.MM00
3VU1300-.MM00
3VU1300-.MN00
3VU1300-.MP00
3VU1300-.MP00
3VU1600-.MP00
3VU1600-.MQ00
3VU1600-.MQ00
3VU1600-.MQ00
3VU1600-.MR00
4 ... 6
6 ... 10
10 ... 16
10 ... 16
14 ... 20
18 ... 25
18 ... 25
22 ... 32
28 ... 40
28 ... 40
28 ... 40
36 ... 50
Tuning
value
in A
4
6
10
10
14
18
18
27
32
39
40
50
Rec. slow-blow
fuse
gL class
6A slow-blow
10A slow-blow
16A slow-blow
16A slow-blow
20A slow-blow
20A slow-blow
20A slow-blow
25A slow-blow
25A slow-blow
35A slow-blow
35A slow-blow
50A slow-blow
Fuses on the secondary side of the matching transformer or if connected to 3x
AC 220V mains.
If fuses are to be placed on the secondary side of the matching transformer or
if the DDC is connected to 3 x 220 V mains, then select the fusing as per the
current in the connecting cable, but not less than 16A (16 A slow-blow fuse or
power circuit breaker 3VU1300-.MM00 ).
1) Note the maximum size of the power circuit breaker as indicated by the
manufacturer !
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
17
3. Electrical Connections - Installation Guidelines
Cross section of the
DDC 1 connecting
cable
Calculate the current in the connecting cable to determine cable cross section.
threephase connection
IL =
IL
SAN
SA N
3 · 230V
= current in connecting lead indicated in A
= connected load indicated in VA
The applicable guidelines must be followed when determining cable cross
sections.
If fuses are placed on the input side only when transformers are used, then
protect the secondary line against short-circuiting.
Recommended cable
for the DDC 1
connecting cable
Ready-made INDRAMAT cables are available as connecting cables for the
DDC 1.2 The recommended cable types and cross sections apply where
INDRAMAT transformers and fuses are used.
The cable recommended in the following table has a current capacity as per
EN 60 204 (VDE 0113) – E mode of installation.
Recommended cable
for three-phase
connections
Recommended secondary
cable with INDRAMAT
autotransformers
individual
readyparts
made
Recommended secondary
cable with INDRAMAT
isolating transformers
individual
readyparts
made
Drive
controllers
Transf.(conn.)
load
in kVA
Connector
on drive
DDC 1.2-N050C
2 and 2.5
3.5 and 4
5
7.5
INS 108/02
INS 108/02
INS 108/02
INS 108/03
INK 250 (1.5mm2)
INK 250 (1.5mm2)
INK 250 (1.5mm2)
INK 202 (2.5mm2)
IKL 234
IKL 234
IKL 234
IKL 241
INK 202 (2.5mm2)
INK 204 (6mm2)
INK 202 (2.5mm2)
INK 202 (2.5mm2)
IKL 241
request
IKL 241
IKL 241
DDC 1.2-N...A
2 and 2.5
3.5 and 4
5 and 7.5
10
12.5
15.18 and 20
25
INS 172/25
INS 172/25
INS 172/25
INS 172/25
INS 172/06
INS 172/10
INS 172/16
INK 202 (2.5mm2)
INK 202 (2.5mm2)
INK 202 (2.5mm2)
INK 203 (4mm2)
INK 204 (6mm2)
INK 205 (10mm2)
INK 206 (16mm2)
IKL 232
IKL 232
IKL 232
IKL 242
IKL 243
IKL 244
IKL 245
INK 202 (2.5mm2)
INK 204 (6mm2)
INK 202 (2.5mm2)
INK 203(4mm2)
INK 204 (6mm2)
INK 205 (10mm2)
INK 206 (16mm2)
IKL 232
IKL 243
IKL 232
IKL 242
IKL 243
IKL 244
IKL 245
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
18
3. Electrical Connections - Installation Guidelines
mains side
(transformer
side)
device side
200
INS172 or
INS108 with
DDC1.2-N050C
L1
L2
L3
PE
1
A
2
B
3
C
yel/gn
D
SBDDC1
Fig. 3.4: Power supply cable for a DDC 1.2
3.5. Transformers
Transformers for installation in control cabinets (IP 00) and transformers in
housing with protection category IP 55 are available for adapting the mains
voltage to the DDC 1 connecting voltage.
Autotransformers for
installation in a control
enclosure
Autotransformers are preferred for adapting voltages (see section 3.3).
Their protection category is IP 00, and their ambient temperature 40°C.
See section 3.6 for available options.
Isolating transformers
for installation in a
control enclosure
For special mains conditions, isolating transformers are recommended (see
section 3.3).
Protection category is IP 00; ambient temperature 40°C.
See section 3.7 for available options.
Autotransformers in IP
55 housing
Autotransformers are preferrably used for adapting voltages (see section 3.3).
Transformers in the housing permit a decentralized installation. This decreases
the power loss in the control cabinet.
If transformers are built into the housing, then the surface of the housing limits
the acceptable loss of power. DST ... /G/ type transformers have been
especially constructed with a high level of protection for operation within the
housing. See section 3.8 for available options.
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
19
3. Electrical Connections - Installation Guidelines
3.6. DST Three-Phase Autotransformers for Mounting
in Control Enclosures
A
B
A
B1
G
vertical type
for foot mounting
Type DST.../S
H
E
F
D
Example:
rating plate
C1
H
E
F
D
K
C
horizontal design
for wall mounting
Type DST.../L
Block
diagram:
Type:
Bj.
DST 2,5/S/380/415/440-220
1993
Prim.: 380-400/415/440 V
440V
U4
415V
U3
380V 400V U2
V4
V3
V2
W4
W3
W2
Sec.:
220V 230V U1
V1
W1
220-230V
a
1)
b
N
S
2,5 kVA
YNa0
T
40/B
f
50/60 Hz
1) max. load: DC 24 V/1 A
AC 230 V/1 A
Dimensions and technical data for threephase autotransformers with
Usec = 220-230 V; Upri = 380-400 V, 415 V, 440 V, 460 V, 500 V, f = 50/60 Hz
Dimensions in mm
Type designations
DST
A
B
B1
C
C1
D
E
F
G
H
K
0.5/ • /380/415/440–220
0.5/ • /380/460/500–220
1.0/ • /380/415/440–220
1.0/ • /380/460/500–220
1.5/ • /380/415/440–220
1.5/ • /380/460/500–220
2.0/ • /380/415/440–220
2.0/ • /380/460/500–220
2.5/ • /380/415/440–220
2.5/ • /380/460/500–220
3.5/ • /380/415/440–220
3.5/ • /380/460/500–220
4.0/ • /380/415/440–220
4.0/ • /380/460/500–220
5.0/ • /380/415/440–220
5.0/ • /380/460/500–220
7.5/ • /380/415/440–220
7.5/ • /380/460/500–220
10/ • /380/415/440–220
10/ • /380/460/500–220
12.5/ • /380/415–220
12.5/ • /440/460–220
12.5/ • /500/525–220
15/ • /380/415–220
15/ • /440/460–220
15/ • /500/525–220
18/ • /380/415–220
18/ • /440/460–220
18/ • /500/525–220
20/ • /380/415–220
20/ • /440/460–220
20/ • /500/525–220
25/ • /380/415–220
25/ • /440/460–220
25/ • /500/525–220
35/ • /380/415–220
35/ • /440/460–220
35/ • /500/525–220
50/ • /380/415–220
50/ • /440/460–220
50/ • /500/525–220
150
150
180
180
180
205
205
240
240
240
240
240
240
240
240
300
300
300
300
300
300
335
335
335
360
360
360
360
360
360
360
420
420
420
420
420
420
420
420
580
580
165
165
190
190
190
210
210
260
260
260
260
260
260
260
260
325
325
325
325
325
325
365
365
365
395
395
395
395
395
395
395
450
450
450
450
450
450
450
450
540
540
170
170
205
205
205
235
235
270
270
270
270
270
270
270
270
340
340
340
340
340
340
380
380
380
400
400
400
400
400
400
400
460
75
90
105
115
115
120
120
120
120
140
140
150
150
155
155
140
155
165
180
195
195
195
195
195
190
190
190
205
205
190
205
215
215
215
245
245
245
275
275
255
265
80
95
100
100
110
110
110
135
135
155
155
165
165
170
170
165
180
195
205
220
220
225
225
225
215
215
215
230
230
215
230
210
125
125
125
150
150
150
170
200
200
200
200
200
200
200
200
250
250
250
250
250
250
280
280
280
300
300
300
300
300
300
300
350
350
350
350
350
350
350
350
550
550
70
70
80
80
80
95
95
110
110
110
110
110
110
110
110
140
140
140
140
140
140
160
160
160
170
170
170
170
170
170
170
190
190
190
190
190
190
190
190
270
270
100
100
125
125
125
145
145
170
170
170
170
170
170
170
170
210
210
210
210
210
210
230
230
230
250
250
250
250
250
250
250
280
280
280
280
280
280
280
280
400
400
154
154
185
185
185
209
209
240
240
240
240
240
240
240
240
310
310
310
310
310
310
350
350
350
370
370
370
370
370
370
370
420
6
6
7
7
7
7
7
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
14
14
14
14
14
14
14
14
18
18
55
70
75
85
85
85
85
90
90
110
110
120
120
125
125
110
125
135
150
165
165
160
160
160
160
160
160
175
175
160
175
165
165
165
195
195
195
225
225
205
215
max. conn. Wgt.
power
loss cross sections in kg
in mm2
in W
30
40
45
55
55
75
80
90
95
110
125
130
140
150
160
180
200
230
245
250
260
270
285
290
305
310
330
350
375
380
395
430
450
470
490
540
630
670
720
790
850
4
4
4
4
4
4
4
4
4
4
10
10
10
10
10
10
10
10
10
10
10
10
10
16
16
16
16
16
16
16
16
16
35
35
35
35
35
35
70
70
70
4
6
8.5
10
10
11.5
11.5
18
18
21
21
24.5
24.5
26
26
30.5
36
42
50
53
53
65
65
65
68
68
68
80
80
70
80
92
92
92
122
122
122
152
152
180
195
MBDST
Fig. 3.5: DST - threephase autotransformers dimensional data
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
20
3. Electrical Connections - Installation Guidelines
3.7. DLT Three-Phase Isolating Transformers for
Mounting in Control Enclosures
A
C1
B1
G1
B
A
Hø
E
F
D
G
C
Hø
E
F
D
vertical design
for foot mounting
Type DLT.../S
Block diagram:
Example: rating plate
Type:
Bj.
DLT 2,5/S/380/415/440-220
1993
1U1, 1V1, 1W1
1U2, 1V2, 1W2
1U3, 1V3, 1W3
2U1, 2V1, 2W1
Prim.: 380-400/415/440 V
Sec.:
S
220-230V
2,5 kVA
horizontal design
for wall mounting
Type DLT.../L
Yyn0
T
40/B
f
440 V
415 V
380 V–400 V
220 V–230 V
50/60 Hz
1U1
1U2
1U3
1V1
1V2
1V3
1W1
1W2
1W3
2U1
a
2V1
2W1
2N1
1)
b
1) Maximum load: DC 24 V/1 A; AC 230 V/1 A
Dimensions and technical data for threephase isolating transformers with
Usec = 220-230 V; Upri = 380-400 V, 415 V, 440 V, 460 V, 500 V, f = 50/60 Hz
Dimensions in mm
Type designations
DLT
A
B
B1
C
C1
D
E
F
G
G1
0.5/ • /380/415/440–220
0.5/ • /380/460/500–220
1.0/ • /380/415/440–220
1.0/ • /380/460/500–220
1.5/ • /380/415/440–220
1.5/ • /380/460/500–220
2.0/ • /380/415/440–220
2.0/ • /380/460/500–220
2.5/ • /380/415/440–220
2.5/ • /380/460/500–220
4.0/ • /380/415/440–220
4.0/ • /380/460/500–220
5.0/ • /380/415/440–220
5.0/ • /380/460/500–220
7.5/ • /380/415/440–220
7.5/ • /380/460/500–220
10/ • /380/415/440–220
10/ • /380/460/500–220
15/ • /380–220
20/ • /380–220
25/ • /380–220
35/ • /380–220
50/ • /380–220
180
180
205
205
240
240
240
240
300
300
300
300
335
335
360
360
360
360
420
420
580
660
660
190
190
210
210
260
260
260
260
325
325
325
325
365
365
395
395
395
395
450
450
540
590
655
205
205
235
235
270
270
270
270
340
340
340
340
380
380
400
400
400
400
105
105
130
130
140
140
150
150
140
140
165
165
175
175
190
190
205
205
245
275
255
295
305
100
100
120
120
155
155
165
165
165
165
195
195
210
210
215
215
230
230
150
150
170
170
200
200
200
200
250
250
250
250
280
280
300
300
300
300
350
400
––
––
––
80
80
95
95
110
110
110
110
140
140
140
140
160
160
170
170
170
170
190
190
270
270
270
125
125
145
145
170
170
170
170
210
210
210
210
230
230
250
250
250
250
280
280
400
480
480
75
75
95
95
110
110
120
120
110
110
135
135
145
145
160
160
175
175
195
225
205
245
255
185
185
209
209
240
240
240
240
310
310
310
310
350
350
370
370
370
370
H
power
loss
in W
max. conn.
cross sections
in mm2
Wgt.
in kg
7
7
7
7
11
11
11
11
11
11
11
11
11
11
11
11
11
11
16
16
18
18
18
65
70
120
140
155
165
180
195
220
235
240
265
300
350
375
395
500
510
600
800
875
1000
1170
4
4
4
4
4
4
4
4
4
4
10
10
10
10
10
10
10
10
16
35
35
70
70
8.5
8.5
13
13
21
21
24.5
24.5
30.5
30.5
42
42
55
55
70
70
85
85
122
152
180
275
320
MBDLT
Fig. 3.6: DLT - threephase isolating transformers dimensional data
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
21
3. Electrical Connections - Installation Guidelines
3.8. Three-Phase Autotransformers in IP 55 Housing
If transformers are to be mounted into housing, then this must be taken into consideration during planning.
Due to the limit heat dissipation via the relatively small housing surface it is possible for standard transformers
to reach unacceptably high temperature levels. Transformers of the type DST../G/ have been especially with a
higher protection level for mounting into housing.
blind screw
H
PG11
C
B
E
PG
G
G
H
F
F
PG
blind
screw
PG11
D
A
C
autotransformers with housing up to 5 kVA
E
B
autotransformers with housing from 10 to 25 kVA
Technical data
Type codes
as per DIN/VDE 0550 and 0532
steel plate housing - prot. category IP 55
powder coating in RAL 7032
connection symbol: YNa0
frequency: 50/60 Hz
insulation class: T 40/F
temperature contact: AC1A/250V/DC24V
Resin coat for protection against corrosion
individual items checked by VDE/IEC
DST 2,5 / G / 400/480/500/525 - 230 - IP55
DST = threephase
autotransformer
rated power
in kVA
suitable for
mounting into
IP55 housing
Block diagram
460 V
440 V
415 V
400 V
D
A
U5
U4
U3
U2
V5
V4
V3
V2
W5
W4
W3
W2
U1
V1
W1
input voltages
in V
output voltages
in V
1)
prot. cate.
230 V
N1
MBDREHSTRSPARTRAFO
1) max. load: DC 24 V/ 1 A
AC 230 V / 1 A
Avilable types
Type Codes
DST .../G/
Dimensions in mm
A
B
C
D
E
G
H
Weight
Pg
Pg
Fø cable ø cable ø in kg
Maximum conn.
cross sections
in mm2
2,5/G/400/415/440/460-230-IP55
16
21
300 445 235 250 415
12
33.5
2.5/G/400/480/500/525-230-IP55
10…14 14…18
5.0/G/400/415/440/460-230-IP55
16
21
375 570 235 300 540
12
54
5.0/G/400/480/500/525-230-IP55
10…14 14…18
10/G/400/415/440/460-230-IP55
16
21
490 400 500 250 370
16
100
10/G/400/480/500/525-230-IP55
10…14 17…19
15/G/400/415/440/460-230-IP55
21
29
595 480 600 280 440
16
135
15/G/400/480/500/525-230-IP55
14…18 18…25
25/G/400/415/440/460-230-IP55
29
36
595 480 600 280 440
16
200
25/G/400/480/500/525-230-IP55
18…25 25…33
Fig. 3.7: Dimensions and data of 3-phase autotransformers (prot. cat. IP 55)
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
4
10
10
16
35
22
3. Electrical Connections - Installation Guidelines
3.9. Motor Power Connection
Ready-made cables
Ready-made cables are available for motor power connections. The motor
power cable can be made available in individual parts upon request.
Maximum cable length
If INDRAMAT motor power cables are used, then maximum cable length is 75
meters.
When operating the DDC 1.2 in residential and light-industrial areas,
it may be necessary to shield the motor power cable to maintain the
values for radio interference transmission (rf interference
suppression).
Motor side
Machine side
A
1
A
B
2
B
C
3
C
D
gn/yel
D
E
5
E
H
6
H
F
7
F
G
8
G
M
ϑ
PTC
U
APMOTLEISTKAB
Fig. 3.8: A shielded motor power cable
The motor power connector controls the holding brakes of the MDD
motors. The holding brake has not been designed to function as a
working brake. It wears down after approximately 20,000 revolutions
against the closed brake.
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
23
3. Electrical Connections - Installation Guidelines
Motor power cable
capacity
The following recommended cable types and cross sections are based on the
current load capacity listed per EN 60 204 (VDE 0113) – E mode of installation.
If other standards are required for the actual application, or if cables are routed
to accomodate a different installation mode, then greater cable cross sections
may be needed.
B1
leads in protective pipes and installation channels
B2
cables and leads in protective pipes and installation channels
C
E
cables and leads on walls and on cable flat beds
MZINSTART
Fig. 3.9: Modes of installation as per EN 60204
cross sections
in mm2
1.5
2.5
4
6
10
16
25
Installation
mode B1
13.5
18.3
25
32
44
60
77
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
Current load as per EN 60 204
in A
Installation
Installation
mode B2
mode C
12.2
16.5
23
29
40
53
67
15.2
21
28
36
50
66
84
Installation
mode E
16.1
22
30
37
52
70
88
24
3. Electrical Connections - Installation Guidelines
Recommended INDRAMAT Motor Power Cables
Motor type
MDD...
DDC 1.2
connector on connector on
motor INS 3)
unit INS 3)
INDRAMAT Cable for Motors Without Cooling
motor phase
current
21...
25...
41...
65A-N-040
65A-N-060
65B-N-040
65B-N-060
65C-N-040
65C-N-060
65D-N-040
65D-N-060
71A-N-030
71A-N-040
71A-N-060
71B-N-030
71B-N-040
71B-N-060
71C-N-030
71C-N-040
71C-N-060
90A-N-020
90A-N-030
90A-N-040
90B-N-020
90B-N-030
90B-N-040
90C-N-020
90C-N-030
90C-N-040
93A-N-020
93A-N-030
93A-N-040
93B-N-020
93B-N-030
93C-N-020
93C-N-030
112A-N-015
112A-N-020
112A-N-030
112A-N-040
112B-N-015
112B-N-020
112B-N-030
112C-N-015
112C-N-020
112D-N-015
115A-N-015
115A-N-020
115A-N-030
-N050C
-N050C
-N050C
-N050C
-N050C
-N050C
252
252
252
252
252
252
252
252
252
252
252
252
252
252
252
108
108
108
108
108
252
252
252
252
108
108
108
108
108
108
108
108
108
108
108
108
108
108
108
108
108
108
108
108
108
108
108
108
108
110
110
110
110
110
110
110
110
110
110
110
110
110
110
110
110
110
110
110
110
110
110
110
110
110
110
110
110
110
110
110
110
110
110
110
110
110
110
110
110
110
110
110
110
110
110
110
110
110
in A
max.1.3
max.3.2
max.8.4
1.5
2.1
2.9
4.8
4.5
6.4
5.2
8.4
3
4.1
6.1
6
9
12.3
8.8
12
18
3.3
5.1
7.7
6.8
10.3
13.7
9.8
15.9
19.9
8.3
14.5
19
13.8
19.6
17.5
26.3
6.8
9.7
14.1
18.8
12.1
17
22.9
18.2
24.3
24.2
17
22.7
22.1
cross
sections
in
mm 2
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
2.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
2.5
1.5
1.5
2.5
1.5
2.5
2.5
4
1.5
1.5
1.5
2.5
1.5
2.5
4
2.5
4
4
2.5
4
4
individual
parts 1)
INK2...
INK6...
250
250
250
250
250
250
250
250
250
250
250
250
250
250
250
250
250
250
250
202
250
250
250
250
250
250
250
250
202
250
250
202
250
202
202
203
250
250
250
202
250
202
203
202
203
203
202
203
203
ready
made
IK. ...
2)
027
027
027
027
027
027
027
027
027
027
027
027
027
027
027
024
024
024
024
044
027
027
027
027
024
024
024
024
044
024
024
044
024
044
044
064
024
024
024
044
024
044
064
044
064
064
044
064
064
1)
INK 2.. for standard, individual cable parts, INK 6.. for individual, shielded cable parts.
2)
IKL… for standard, ready made cables, IKG… for shielded, ready-made cables.
3)
For a complete list of all connector types see "Connecting accessories for INDRAMAT drives".
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
25
3. Electrical Connections - Installation Guidelines
Recommended INDRAMAT Motor Power Cables
Motor type
MDD...
DDC 1.2
connector on connector on
motor INS 3)
unit INS 3)
INDRAMAT Cable for Motors With Cooling
motor phase
current
71B-N-040
71B-N-060
71C-N-030
71C-N-040
71C-N-060
90B-N-030
90B-N-040
90C-N-020
90C-N-030
90C-N-040
93A-N-020
93A-N-030
93A-N-040
93A-N-060
93B-N-020
93B-N-030
93B-N-040
93B-N-060
93C-N-020
93C-N-030
93C-N-040
93C-N-060
112A-N-015
112A-N-020
112A-N-030
112A-N-040
112B-N-015
112B-N-020
112B-N-030
112B-L-030
112B-N-040
112C-N-015
112C-N-020
112C-L-020
112C-N-030
112C-N-040
112D-N-015
112D-L-015
112D-N-020
112D-N-030
115A-N-015
115A-N-020
115A-L-020
115A-N-030
115B-N-015
115B-L-015
115B-N-020
115B-N-030
115C-N-015
115C-N-020
115C-N-030
115D-N-015
115D-N-020
-N…A
-N…A
-N…A
-N...A
-N...A
108
108
108
108
108
108
108
108
108
108
108
108
108
172
108
108
172
172
108
108
172
172
108
108
108
108
108
108
108
172
172
108
108
172
172
172
108
172
172
172
108
108
172
172
108
172
172
172
172
172
172
172
172
217
217
217
217
217
217
217
217
217
217
217
217
217
217
217
217
217
217
217
217
217
217
217
217
217
217
217
217
217
217
217
217
217
217
217
217
217
217
217
217
217
217
217
217
217
217
217
217
217
217
217
217
217
in A
9
12.3
8.8
12
18
10.3
13.7
9.9
15.9
19.9
8.3
14.5
19
30.1
13.8
19.6
29.9
38.2
17.5
26.3
37
53.2
6.8
9.7
14.1
18.8
12.1
17
22.9
22.9
33.9
18.2
24.3
24.3
35.4
47.5
24.2
24.2
35.8
49.5
17
22.7
22.7
34.6
22.1
22.1
34.6
66.8
32.8
42.1
62.9
31.5
62.9
cross
sections
in
mm2
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
6
2.5
2.5
6
10
2.5
4
10
16
2.5
2.5
2.5
2.5
2.5
2.5
4
6
6
2.5
4
6
6
10
4
6
6
10
2.5
4
6
6
4
6
6
16
6
10
16
6
16
individual
parts 1)
INK2...
INK4...
202
202
202
202
202
202
202
202
202
202
202
202
202
204
202
202
204
205
202
203
205
206
202
202
202
202
202
202
203
204
204
202
203
204
204
205
203
204
204
205
202
203
204
204
203
204
204
206
204
205
206
204
206
ready
made
IK. ...
2)
050
050
050
050
050
024
024
024
024
044
050
050
050
103
050
050
103
123
050
068
123
143
050
050
050
050
050
050
068
103
103
050
068
103
103
123
068
103
103
123
050
068
103
103
068
103
103
143
103
123
143
103
143
)
INK 2.. for standard, individual cable parts, INK 6.. for individual, shielded cable parts.
2)
IKL… for standard, ready made cables, IKG… for shielded, ready-made cables.
3)
For a complete list of all connector types see "Connecting accessories for INDRAMAT drives".
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
26
3. Electrical Connections - Installation Guidelines
3.10. Motor Feedback Connection
Feedback Connection
The feedback connections for motors with digital servo feedback (DSF) and
resolver feedback (RSF) are built into cable leadthroughs inside the DDC 1,
at terminal X4 (see section 4). Ready-made cables are also available.
MDD motors with digital servo feedback can only be operated with
DDC 1.2-.....-D...-XX and motors with resolver feedback only with
DDC 1.2-.....-R...-XX units.
Only those motor/drive combinations listed in the configuration
sheets may be operated together.
Maximum cable length
Connector
assignments for DSF
and RSF
Maximum cable length is 75 meters if INDRAMAT feedback cables are used.
Feedback cable INK 209
8 x0.25mm2 + 2 x 1.0mm2
controller side
1
4
1mm2
12
1mm2
motor side
9
WH (ws)
BN (bn)
10 OV
12 UG or R1
8
VT (vio)
7
SDO
15
BU (bl)
4
SDI
14
BK (sw)
3
FS
7
RD (rt)
2
SCL
3
PK (rs)
1
C- or S4
10
GY (gr)
8
C+ or S2
2
GN (gn)
6
S- or S3
9
BN (bn)
5
S+ or S1
soldering side
15
9
soldering side
1
2 10
3
1
4
8
9
11
8
12 7
6
5
APSTECKMOT
Fig. 3.10: Motor feedback terminal assignments
IKS 374/...
INS 290
IKS 375/...1)
INS 290
INS 513
INK 209
INS 511
INK 209
1) Do not use with axially surface-cooled motors MDD 112 and 115.
Konfkabel
Ready-made
INDRAMAT
feedback cables
for MDD motors
Fig. 3.11: Ready-made INDRAMAT feedback cables
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
27
3. Electrical Connections - Installation Guidelines
3.11. Interface to NC Control Unit
Ready-made cable
Maximum cable length
Interface X8 connects the DDC to the machine control unit. Ready-made
cable, IKS083, is available for this purpose.
Maximum cable length is 20 meters if ready-made cable IKS 083 is used.
IKS 083/...
INS 478
150
INK 271
(34 x 0.25 + 2 x 0.5)
screwed connection
part no.: 258 787
DDC X8
Ferrules
0.25mm2
1
WH (ws)
2
BN (bn)
0.25mm2
3
YE (ge)
0.25mm2
4
PK (rs)
0.25mm2
5
BU (bl)
0.25mm2
6
RD (rt)
0.25mm2
7
BK (sw)
0.25mm2
8
VT (vio)
0.25mm2
9
GY-PK (gr-rs)
0.25mm2
10
RD-BU (rt-bl)
0.25mm2
11
WH-GN (bn-gn)
0.25mm2
12
BN-GN (bn-gn)
0.25mm2
WH-YE (ws-ge)
0.25mm2
YE-BN (ge-bn)
0.25mm2
15
WH-GY (ws-gr)
0.25mm2
16
GY-BN (gr-bn)
0.25mm2
17
WH-PK (ws-rs)
0.25mm2
18
PK-BN (rs-bn)
0.25mm2
19
WH-BU (ws-bl)
0.25mm2
20
BN-BU (bn-bl)
0.25mm2
21
WH-RD (ws-rt)
0.25mm2
22
BN-RD (bn-rt)
0.25mm2
23
WH-BK (ws-sw)
0.25mm2
24
GN (gn)
0.5mm2
GY (gr)
0.5mm2
27
BN-BK (bn-sw)
0.25mm2
28
GY-GN (gr-gn)
0.25mm2
29
YE-GY (ge-gr)
0.25mm2
30
PK-GN (rs-gn)
0.25mm2
YE-PK (ge-rs)
0.25mm2
GN-BU (gn-bl)
0.25mm2
YE-BU (ge-bl)
0.25mm2
GN-RD (gn-rt)
0.25mm2
YE-RD (ge-rt)
0.25mm2
GN-BK (gn-sw)
0.25mm2
YE-BK (ge-sw)
0.25mm2
13
14
free
25
Acknowledge Power Off (K1)
Acknowledge Power On (K1)
do not assign!
drive enable signal (Bb)
power infeed working (UD)
bleeder temperature prewarning (BVW)
free
ZKS
power
OFF
control
ON
+15VM
signal voltages
0VM
for measuring
-15VM
and testing
+24VL
purposes
0VL
26
free
infeed
shield connection for
cable expansion or
not assigned
free
APKONSCHNKAB
Fig. 3.12: Ready-made interface cable IKS 083
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
28
3. Electrical Connections - Installation Guidelines
3.12. Control Circuit of the DDC Mains Contactor
The general operating method as suggested by INDRAMAT is to control the
mains contactor and dynamic braking in the DDC. Selection of the control
method and its effects will depend on the functions offered and the responses
of the entire system. It is, therefore, the responsibility of the machine builder.
Standstill with fault in
drive electronics with/
without DC bus
dynamic braking
With dynamic braking, synchronous motors are always braked to a standstill
(MAC or MDD) whether electronic circuitry in the drive is still operational or not.
The dynamic brake functions as an additional protective device for the
machine.
Inductance motors (2AD or 1MB) are not braked when the DC bus is shortcircuited.
Without dynamic braking, properly functioning drives can be braked at
maximum torque. However, if there is trouble in the closed-loop electronic
control system or if there is a discontinuity in the feedback line, it should be
expected that drives will coast without electrical braking. Dynamic braking can
only be eliminated when non-braked deceleration does not damage the
system. As an alternative, motors equipped with mechanical holding brakes
can be used.
How to stop the drive in the event of a fault will depend on the
functions offered on the system. In the final analysis, this decision
can only be reached by the system designer. Thus, the following
recommended is intended only as a guide to the system designer.
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
29
3. Electrical Connections - Installation Guidelines
3.13. Control Circuit in the DDC with Dynamic Braking
Application
This control circuit should be selected if a synchronous motor, e.g., MDD, is
connected to the DDC.
Features
Dynamic braking always brakes synchronous motors to a standstill whether
or not the drive electronics are operational. The DC bus is only short-circuited
with a drive fault.
In the event of an emergency stop (E-stop) or a disconnect, the drives are
braked to a standstill at maximum torque by the drive electronics.
Operating principle
If the ON button is pressed, then auxiliary relays K3 and K4 switch mains
contactor K1 on. Should K3 or K4 fail, then power cannot be switched on.
If the E-stop button is pressed, then K3 and K4 safely switch off mains
contactor K1. The NC control unit of the machine must simultaneously lock out
the drive enable (RF input with analog interface, E-STOP input of a DEA with
a DLC single axis posititioning module). The command value of the drive is
then switched to zero. There is a controlled braking of the drive.
A drive error signal from the Bb contact of the DDC, an error signal from the
controller (servo error) or an overtravelling of the limit switch disconnects the
mains contactor and triggers dynamic braking.
The signal sequence as depicted in the diagram below is recommended for
commissioning the DDC.
Output
signal
Input
signal
DC bus
dynamic brake
OFF
ON
1)RF
E-stop
2)CLEAR
2)START
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
t1
t1
t1
t2
t1
t2
t2
UD contact
t3
t3
t3
t4
t3
t4
t4
2) automatic
mode
t5
t4
t5
t4
t5
t4
SVDDC01
t1 > 3 s; t2 > 100 ms; t3 > 10 ms; t4 >= 20 ms; t5 > 0.3 s
1) Drive enable signal in drives with analog interface or E-stop input in
drives with DLC positioning module.
2) Applies only to drives with DLC positioning module.
Fig. 3.13: Signal path diagram for switching on a DDC
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
30
3. Electrical Connections - Installation Guidelines
Control circuit of the DDC • with DC bus dynamic brake
• with E-stop, regulated braking by the drive electronics
PE
L1
3 x AC
(50-60Hz) L2
L3
F1
Q10
autotransformer
DST
3 x AC 230V
X7 A
B
C
D
DC 24V
X8/15
X8/7
K1
Bb
ZKS
X8/8
S2
D
NC
X8/16
1
A
X8/17
motor
power
connection
S1
OFF
B
ZKS
S4
C
X8/18
machine NC control
X5
K3
X7/A
X8/19
ON
X8/9
machine E-stop
K3
S5
UD
X8/10
X8/20
K3
2)
&
K4
K4
on impulse
min. 100 ms
S1
+24 V
K4
K1
1) drive
enable
X7/B
ready
= ready
= power supply fuse
= mains contactor in DDC
= auxiliary relay for switching K1
= auxiliary relay for switching K1
= error message of the NC controls
- open with faulty drive (servo error)
- closed with E-stop
Q10 = main switch
Bb
F1
K1
K3
K4
NC
S1
S2
S4
S5
= E-stop
= end positon of axis
= power off
= power on
SSANSTNETZZW
1) Drive enable signal
• drive enable input with analog interface
• E-stop input with DLC
2) Only applies to DLC single-axis positioning modules
If the NC control unit of the machine switches the E-stop input of the DLC off when the UD contact is open, then the message
"E-stop" is stored with each powering down. The NC control unit of the machine can, during the course of one program cycle and
prior to starting the program, clear the message "E-stop" with a CLEAR signal. Under some circumstances, error diagnoses can be
cancelled. It is not necessary to switch the E-stop input of the DLC off as part of a general powering down. As part of a general
powering down, the NC controls of the machine can, for example, suppress the evaluation of the UD contact. The NC control of the
machine cannot, however, start the program if the UD contact is closed.
Fig. 3.14: Control circuit of the DDC mains contactor with dynamic brake
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
31
3. Electrical Connections - Installation Guidelines
3.14. Control circuit of the DDC Mains Contactor
Without Dynamic Braking
Application
• if an inductance motor is mounted to a DDC ( 2AD; 1MB; LAF; LAR )
• if uncontrolled coasting cannot damage the installation.
Features
The DC bus is not short-circuited. There can be no controlled braking of
inductance drives if the DC bus is short-circuited.
The drives are braked by the drive electronics at maximum torque for an E-stop
or a power disconnect.
Operational principle
If the E-stop sequence is triggered, then K3 and K4 safely switch off mains
contactor K1. The NC control unit of the machine simultaneously locks out the
drive enable (RF input with analog interface, E-stop input of a DEA with a DLC
single-axis positioning module). The command value of the drive is switched
to zero. There is a controlled braking of the drive.
The drives coast uncontrolled with a fault in the drive electronics. The
short circuiting of the DC bus can only be dispensed with if a coasting
of the drives cannot damage the facility. Motors with mechanical
holding brakes can be used as an alternative.
The signal sequence depicted in the diagram below is recommended.
Output
signal
Input
signal
OFF
ON
1)RF
E-stop
2)CLEAR
2)START
1
0
1
0
1
0
1
0
1
0
1
0
1
0
t1 t
2
t1 t
2
UD contact
t3
t3
t3
t4
t4
2) automatic
mode
t5
t4
t5
t4
t1> 3 s; t2 > 100 ms; t3 > 10 ms; t4 >= 20 ms; t5 > 0.3 s
SVDDC02
1) Drive enable signal in drives with analog interface or E-stop
input in drives with DLC positioning module.
2) Applies only to drives with DLC positioning modules.
Fig. 3.15: Signal path diagram for switching on a DDC
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
32
3. Electrical Connections - Installation Guidelines
DDC control
• without DC bus dynamic brake
• regulated braking by the drive electronics with an E-stop
PE
L1
3 x AC
(50-60Hz) L2
L3
F1
Q10
autotransformer
DST
3 x AC 230V
X7 A
X8/15
B
C
D
DC 24V
K1
D
X8/16
1
A
X8/17
motor power
connection
S1
OFF
B
ZKS
S4
C
X8/18
X5
K3
X7/A
machine NC control
X8/19
K3
S5
ON
X8/9
machine E-stop
UD
K4
K4
X8/10
on impulse
min. 100 ms
K3
S1
+24 V
X8/20
K4
2)
&
K1
X7/B
enable
1) signal
ready
Bb
F1
K1
K3
K4
NC
= ready
= power supply fuse
= mains contactor in DDC
= auxiliary relay for switching K1
= auxiliary relay for switching K1
= error message of the NC controls
- open with faulty drive (servo error)
- closed with E-stop
Q10 = main switch
S1
S2
S4
S5
1) Drive enable signal
• drive enable input with analog interface
• E-stop input with DLC
= E-stop
= end positon of axis
= power off
= power on
SSANSTNETZOZW
2) Only applies to DLC single-axis positioning modules
If the NC control unit of the machine switches the E-stop input of the DLC off when the UD contact is open, then the message
"E-stop" is stored with each powering down. The NC control unit of the machine can, during the course of one program cycle and
prior to starting the program, clear the message "E-stop" with a CLEAR signal. Under some circumstances, error diagnoses can be
cancelled. It is not necessary to switch the E-stop input of the DLC off as part of a general powering down. As part of a general
powering down, the NC controls of the machine can, for example, suppress the evaluation of the UD contact. The NC control of the
machine cannot, however, start the program if the UD contact is closed.
Fig. 3.16: Control circuit of the mains contactor in a DDC without dynamic braking
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
33
3. Electrical Connections - Installation Guidelines
3.15. Control Circuit of the DDC Mains Contactor with
E-Stop Relays
Application
• if several E-stop switches are needed in larger installations or if, e.g., a
safety door monitor is required or
• if a synchronous motor (MDD) is connected to the DDC.
Features
Dynamic braking always brakes synchronous motors to a standstill whether or
not the drives electronics are operational. The DC bus is only short-circuited
if there is a drive fault.
In the event of an emergency stop (E-stop) or a disconnect, the drives are
braked to a standstill at maximum torque by the drive electronics.
Operating Principle
If the ON button is pressed, then K3 and K4 safely switch on mains contactor
K1. Should K3 or K4 fail, then power cannot be switched on.
If the E-stop button is pressed, then K3 and K4 safely switch off mains
contactor K1. The NC control unit of the machine must simutlaneously lockout
the drive enable (RF input with analog interface, E-stop input of a DEA 3 with
DLC single-axis postioning module). The command value of the drive is then
switched to zero.
A drive error signal from the Bb contact of the DDC, an error signal from the
controller (servo error), or an overtravelling of the limit switch disconnects the
mains contator and triggers dynamic braking.
The signal sequence as depicted in the diagram below is recommended for
commissioning the DDC.
Output
signal
Input
signal
DC bus dynamic
brake
OFF
ON
1)RF
E-stop
2)CLEAR
2)START
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
t1
t1
UD contact
t3
t3
t3
t3
t4
t4
t4
2) automatic
mode
t5
t4
t5
t4
t5 t
4
SVDDC03
t1 > 3 s; t3 > 10 ms; t4 >= 20 ms; t5 > 0.3 s
1) Drive enable signal in drives with analog interface or E-stop
input in drives with DLC positioning modules.
2) Only applies to drives with DLC positioning modules
Fig. 3.17: Signal path diagram for switching on a DDC
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
34
3. Electrical Connections - Installation Guidelines
NC control unit of DDC • with DC bus dynamic brake
• if an E-stop relay is implemented
PE
L1
3 x AC
(50-60Hz) L2
L3
F1
Q10
autotransformator
DST
3 x AC 230V
X7 A
B
C
D
DC 24V
X8/15
X8/7
K1
Bb
ZKS
X8/8
S2
D
NC
X8/16
1
A
X8/17
K10
OFF
ZKS
X8/18
K3
C
X7/A
machine NC control
X5
X8/19
K3
ON
X8/9
X8/20
K10
+24 V
machine E-stop
K4
K4
UD
X8/10
K3
motor
power
connection
B
K4
2)
&
K1
X7/B
ready
1)
= ready
= power supply fuse
= mains contactor in DDC
= auxiliary relay for switching K1
= auxiliary relay for switching K1
= E-stop relay
= error message of the NC controls
- open with faulty drive (servo error)
- closed with E-stop
Q10 = main switch
S1 = E-stop
S2 = end positon of axis
S4 = power off
S5 = power on
S11 = safety door monitoring
S12 = safety door monitoring
Bb
F1
K1
K3
K4
K10
NC
1) Drive enable signal
• drive enable input with analog interface
• E-stop input with DLC
drive
enable
Control voltage
K1
S4
S11
S1
S5
K10
S12
safety door
closed
E-stop relay
Example: Depending on safety requirements at the machine,
additional monitoring capabilities or locking devices may be
necessary!
SSANSTNETZZWSCHT
2) Only applies to DLC single-axis positioning modules
If the NC control unit of the machine switches the E-stop input of the DLC off when the UD contact is open, then the message
"E-stop" is stored with each powering down. The NC control unit of the machine can, during the course of one program cycle and
prior to starting the program, clear the message "E-stop" with a CLEAR signal. Under some circumstances, error diagnoses can be
cancelled. It is not necessary to switch the E-stop input of the DLC off as part of a general powering down. As part of a general
powering down, the NC controls of the machine can, for example, suppress the evaluation of the UD contact. The NC control of the
machine cannot, however, start the program if the UD contact is closed.
Fig. 3.18:
DDC mains contactor with dynamic brake and safety door monitor
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
35
3. Electrical Connections - Installation Guidelines
3.16. Control Inputs
DC bus dynamic brake
Connector:X8/15-X8/16
Voltage: 24V DC
Current consumption: 150 mA
Input
ZKS
Operating state
open
closed
Power OFF
DC bus dynamic braking
active
Power ON
DC bus dynamic braking
not active
The mains contactor on a DDC cannot be turned on unless ZKS input is
closed. As an additional feature, when trouble occurs in the electronic system
of the drive, the drive can be braked to a stop by opening the ZKS input. This
causes the bus voltage to shorted internally in the DKC. The DC bus dynamic
brake is an additional machine protection.
Power OFF
Connector X8/17-X8/18
Voltage: 24V DC
Current consumption: 150 mA
Input
OFF
open
closed
Operating state
Power OFF
Power ON
Only when the input is closed can the mains contactor be activated. If the Off
input is opened, e.g., with an E-stop, then the mains contactor on the DDC is
turned off immediately. However, the internal bus is not shorted.
Power ON
Connector X8/19-X8/20
Voltage: 24V DC
Current consumption: 150 mA
Input
ON
open
closed or open and
self-holding closed
Operating state
Power OFF
Power ON
If the ZKS and the OFF inputs are closed and the device is ready, closing the
ON input will perform a soft start for the power section in the DDC. The mains
contactor then goes to a self-holding state. The activating pulse must be
present for approximately 100 ms.
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
36
3. Electrical Connections - Installation Guidelines
3.17. Signal and Diagnostics Outputs
Ready state
Zero potential contact - Connector X8/7-X8/8
Maximum load: DC 24V/1A (do not attach higher voltages!)
Operating state
Relay
power off
Error
ready
Output Bb
open
open
closed
The Bb contact signals that the drive is ready for powering up.
Internal interlocking devices will not permit the mains contactor in the DDC to
be turned on until it is closed. The mains contactor is deactivated and the Bb
contact opened with an error. Once the Bb contact opens, there can be no
controlled deceleration of the drives. It can, therefore, be used to trip the
dynamic brake.
DC bus voltage
working
Zero potential contact - Connector X8/9-X8/10
Maximum load: DC 24V/1A
AC 250V/1A
Operating state
Relay
power off
Error
Power
working
Output UD
open
open
closed
The UD contact is closed if the DC bus voltage is greater than 200 V and the
mains contactor is turned on.
The UD contact can be used as a prerequisite for releasing the feed function.
Bleeder Prewarning
Zero potential contact - Connector X8/11-X8/12
Maximum load: DC 24V/1A
AC 250V/1A
Operating state
Relay
power off
Bleeder
load too
high
Bleeder
load within
permissible limits
Output BVW
open
open
closed
The bleeder warning contact opens, if continuous regenerated power is
greater than 75% of continuous bleeder power. Should the bleeder load
continue to climb to thermal overload, then the power supply to the DDC is
discontinued.
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
37
3. Electrical Connections - Installation Guidelines
Mains contactor picked
up
Zero potential contact - Connector X8/3-X8/4
Maximum load: DC 24V/10A
AC 230V/6A
Operating state
contactor dropped
contactor picked up
Output Power ON
open
closed
It can be queried at output power ON whether the mains contactor has been
switched on. The closed contact can be used as a condition for the drive
enable signal.
Mains contactor
dropped out
Zero potential contact - Connector X8/1-X8/2
Maximum load: DC 24V/10A
AC 230V/6A
Operating state
contactor dropped
contactor picked up
Output Power OFF
closed
open
It can be queried at output OFF whether the mains contactor has dropped out.
This information can, for example, be used as a condition to release the door
locking device.
Analog diagnoses
outputs AK1 and AK2
For diagnostics purposes, drive data can be output at analog outputs AK1 and
AK2. Which drive quantities are output is determined at commissioning.
Output voltage: ± 10 V
Load capacity: 4 mA
3.18. Signal Voltages
It is possible to tap off ± 15V and +24V at connector X8. These connections
are specifically used for measuring and test purposes. Should these voltages
be applied outside of the DDC, then no interference voltages may be coupled
in (short and shielded supply lines).
The signal voltage outputs are short-circuit proof. Maximum load
should not be exceeded, otherwise the drive could be damaged.
X8/21
+15VM
measuring voltage
max.100mA
X8/22
0VM
reference potential
measuring voltage
X8/23
-15VM
measuring voltage
max.100mA
X8/24
+24VL
load voltage
max.100mA
X8/25
0VL
X8/26
ground
reference potential
+24VL
shield
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
38
3. Electrical Connections - Installation Guidelines
3.19. Reading Drive Parameters
RS 232 Interface
A VT 100 terminal or a PC with a VT 100 emulation program can be connected
at connector X2 via an RS 232 interface to a DDC drive with analog command
value input or with a single-axis positioning module.
Drive parameters, such as amplilfication of velocity loops, can be output and
optimized, if necessary, via these interfaces at the time of commissioning.
Fault diagnostics are displayed in plain text in the event that service is needed.
Ready-made service cable INK 391 is available for connecting the DDC to a
PC (available lengths: 2, 5, 10 and 15 meters).
connector X2
15 puin Dsub,
miniature plug
9-pin Dsub,
bushing
SYSTEMKONFIGURATION
TxD
RxD
RTS
CTS
SGND
3 TxD
2 RxD
7 RTS
8 CTS
5 SGND
4 DTR
6 DSR
2
3
4
5
7
housing
Service cable INK 391
Serial interface:
V24, RS 232C
SBSer
Fig. 3.19: RS 232 interface
3.20. Regenerated Power
During braking, the energy stored in the drive is absorbed by the bleeder in the
DDC. Do not exceed continuous bleeder power. See data sheets for precise
data.
Continuous bleeder
power
Continuous bleeder power is dependent upon rotary drive energy, potential
energy of unbalaned mass and the number of machine cycles completed.
P RD =
PRD
tz
Wpotg
Wrotg
=
=
=
=
W rotg + W potg
tz
continuous regenerated power or cont. bleeder power in kW
cycle time in s
sum of potential energy in kWs
sum of rotary energy in kWs
When operating main drives in particular (2AD and 1MB), check
whether continuous bleeder power and maximum regenerated energy
during braking are not exceeded -- as per the data sheets.
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
39
3. Electrical Connections - Installation Guidelines
3.21. Fault Current Protective Device
Capacitive discharge currents always flow to earth in switch-mode drives.
The extent of the discharge current is dependent upon:
• the number of drives used,
• the length of the motor power cable,
• the motor type and
• the ground conditions at the installation site.
The discharge current is unavoidably increased, if measures are taken to
improve the electromagnetic compatibility (EMC) of the machine (mains filters
or shielded cables).
FI current limiting circuit breakers with a nominal fault current smaller than
0.3 A should not be used!
Switching inductors on, e.g., transformers, contactors or electromagnetic
valves, can cause false tripping.
The safety of electronic equipment with three-phase bridge
connections, B6 switches, cannot be guaranteed if commercial,
pulse-current sensitive FI protective circuit breakers are used. For
this reason, FI circuit breakers should not represent the only safety
measures taken.
3.22. High-Voltage Testing
Connect only those voltages outlined in the data sheets or in the
interface descriptions.
Remove all connections to the DDC 1 before performing any high
voltage checks.
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
40
4. Mounting the DDC 1.2
4.
Mounting the DDC 1.2
The protection category of the DDC 1.2 is IP 65. It can be directly mounted to
the feeding device. Long cable connections susceptible to interference are
thus avoided.
7
25
9.5
7.5
4.1. DDC 1.2-N - dimensional data
470
interface to
NC control
of machine
motor
power
conn.
mains connection
(22.5)
interface to
NC control
of machine
MBDDC
298
275
165
space for
cable
140
7
(10)
40
shroud
635
517.5
500
shroud
13
220
Fig. 4.1: DDC 1.2 - dimensional data
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
41
4. Mounting the DDC 1.2
4.2. Front View of DDC 1.2-N
fault
reset
key (S1)
slot for
software
module (U5)
SYSTEMKONFIGURATION
status
display
warning
and error
messages (H1)
configuration
rating plate
RS-232
interface
for connecting
VT-100
terminal
or PC (X2)
slot for
command
module (U1)
analog
inputs and
outputs
(X3)
motor
feedback (X4)
connection
additional
slots
(U2, U3, U4)
for auxiliary
plug-in
modules
cable
leadthrough
interface to the
NC controls of
machine
motor power
connection
mains connection
FADDC
Fig. 4.2: Front view of DDC 1.2-N
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
42
4. Mounting the DDC 1.2
4.3. Power Connections
The protection category of the power terminal connectors (X7) of the DDC, the
motor power terminal (X5), and the NC control unit interface (X8) is IP 65.
The motor feedback cable and the connections for the optional plug-in cards
are inserted in the DDC. These connections run through the cable leadthrough
along the underside of the DDC. These must be carefully installed to maintain
the IP 65 protection category.
D
D
1
Installation guidelines
for cable leadthrough
4
C
2
3
1. release screw 1
2. open shroud 2
3. release knurled screw 3
4. remove cover 4
5. remove gasket 5
6. place cable in gasket 6
7. reverse mounting order for closing up
8. tighten screw 1
5
EXDDC
Fig. 4.3: Installing the cable leadthrough
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
43
4. Mounting the DDC 1.2
4.4. Minimum Clearances
During installation, make sure that the air outlet is not obstructed and the bend
radii of the cables are maintained.
Minimum clearance equals allowance for power connectors plus bend radius,
but not smaller than 300 mm.
Bend radii of
INDRAMAT cables
Type
Power
core
diameter
(mm2)
INK 250
1.5
11.4 ± 0.4
70
110
INK 202
2.5
17.6 +0.3/-0.5
120
200
INK 203
4.0
18.6 ± 0.5
120
270
INK 204
6.0
20 ± 0.5
120
300
INK 205
10.0
25.4 ± 0.5
200
380
INK 206
16.0
26.6 ± 0.5
220
390
INK 207
25.0
30.6 ± 0.7
240
430
INK 650
1.5
12.2 ± 0.4
80
120
INK 602
2.5
14.8 ± 0.5
85
140
INK 603
4.0
16.9 ± 0.5
110
180
INK 604
6.0
18.8 ± 0.6
120
195
INK 605
10.0
23.8 ± 0.5
150
240
INK 606
16.0
28.2 ± 0.6
160
280
INK 607
25.0
29.5 ± 0.6
190
290
1)
Power
cable
diameter
(mm)
Minimum Bend Radius
fixed routing
(mm)
flexible routing 1)
(mm)
Service life greater than 500 000 bend loads.
Fig. 4.4: Bend radii of INDRAMAT cables
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
44
4. Mounting the DDC 1.2
The bleeder resistor in the DDC heats up during operation. Flammable
materials or parts which could deform in the hot air stream, e.g., polyvinylchloride
cable conduits, must maintain a minimum clearance of 300 mm to the air
outlet.
air outlet
air outlet
≥ 300
Safety Clearances
SYSTEMKONFIGURATION
heatsink
rB
rB = bend radius
≥ bend radius
bleeder
FPLufteinaus
Fig. 4.5: DDC - air inlet and outlet and position of bleeder resistor
The DDC 1.2 generally needs no maintenance. If it is operated in a
very dirty environment, and if heatsink could become clogged, e.g.,
by foundry dust, then these should be regularly checked. If the device
function is inhibited by dirt, then both the blower and the heatsink
should be cleaned.
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
45
5. Order Informationen
5.
Ordering Information
5.1. Type Codes for the DDC 1.2
Example: D D C
1 . 2 - N 0 5 0 A - D A 0 7 - 0 1 - FW
1.
1.1
Product name
DDC . . . . . . . . = DDC
2.
2.1
Series
1 . . . . . . . . . . . . . . . . . . . .= 1
3.
3.1
Version
2........................=2
4.
4.1
4.2
Cooling type
liquid. . . . . . . . . . . . . . . . . . . . . . . . . .
air, natural convection . . . . . . . .
5.
5.1
5.2
5.3
Rated current
50 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = 050
100 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = 100
200 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = 200
6.
6.1
6.2
Noise emission at motor
Standard (100 A ... 200 A rated current) . . . . . . . . . = A
=C
Standard (50 A rated current) (reduced noise).
7.
7.1
7.2
Motor feedback
=D
Digital servo feedback . . . . . . . . . . . . . . . . . . . . .
Resolver feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . = R
8.
8.1
8.2
8.3
8.4
Command module
ANALOG interface . . . . . . . . . . . . . . . . . . . . . . . . . . = A
INTERBUS-S interface . . . . . . . . . . . . . . . . . . . . . . . = C
Single-axis positioning control . . . . . . . . . . . . . . . . . .= L
SERCOS interface . . . . . . . . . . . . . . . . . . . . . . . . . . = S
9.
9.1
Function code
01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = 01
=F
=K
10. Function code version
10.1 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = 01
11. Firmware
11.1 Identify firmware as item that must
be ordered separately.
= FW
TLDDC
Fig. 5.1: DDC 1 - type codes
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
46
5. Order Informationen
5.2. Accessories for Connections
The following connectors and connector sets are available where ready-made
cables are not used.
Individual IP 65
connectors
IP 65 connectors are used for the power connections of the DDC, motor power
cable connections and the NC control unit connections.
Name
Connector type
Power connection
DDC 1.2-N050C
DDC 1.2-N ... A
INS 108/.. 1)
INS 172/..
Motor power cable
DDC 1.2-N050C
DDC 1.2-N ... A
INS 110/..2)
INS 217/..
Connection to machine NC control unit
1) For complete types see 3.4
INS 478
2) For complete types see 3.10
The plug-in module connections are inserted in the DDC 1. Select the relevant
connector set (S..-DDS 2) after discussing your requirements with your
INDRAMAT Sales Office.
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
47
5. Order Informationen
Individual connector
sets
If ready-made cable sets are only partially used, then the still required
connectors for the plug-in modules can be ordered separately.
Components
Conn.
strip
Name of
plug-in connector
Part
numer
Text
Comment
DDS 2, DDS 3
drive controller
X4
231 715
CONN. INS290
DKS 1
drive controller
X4
231 715
CONN. INS290
DSS 1.1, DSS 1.3,
DSS 2.1
SERCOS Interface
X10
plug-in connector for
feedback conn.,15 pin
Dsub, male
plug-in connector for
feedback connection, 15 pin
Dsub, male
plug-in connector for
LWL cable (fiber optic cable)
244 069
or
244 062
244 069
CONN. INS420
or
CONN. INS425
CONN. INS420
or
CONN. INS425
plug-in connector not needed
with
ready-made feedback cable
plug-in connector not needed
with
ready-made feedback cable
INS420 for LWL cable INK414
with 2,2mm Ø for control encl.
internal connections
X11
plug-in connector for
LWL cable
244 062
X12
DAE 1.1
X13
ANALOG Interface with
incremental encoder
emulator
X14
DAA 1.1
X15
ANALOG Interface with
absolute encoder
emulator
X16
DZF 1.1
gear toothed interface
DLF 1.1
high-resolution
position interface
(Sine signal)
DEF 1.1
incremental
position interface
(squarewave signal)
DEF 2.1
incremental
position interface
(squarewave signal)
DEA 4.1
Inputs/outputs
(I/O) module
DEA 5.1
Inputs and outputs
(I/O) module
DEA 6.1
Inputs/outputs
(I/O) module
DLC 1.1
Positioning module
X20
X23
9 pin plug-in terminal
241 591
CONN.-KL3,81 F
MC 1,5/ 9ST B 1-9
CONN.-KL3,81 F
MC 1,5/10ST B 1-10
10 pin plug-in terminal
241 647
15 pin Dsub,
female
10 pin plug-in terminal
231 714
CONN. INS289
241 647
CONN.-KL3,81 F
MC 1,5/10ST B 1-10
15 pin Dsub,
female
15 pin Dsub,
male
15 pin Dsub,
male
231 714
CONN. INS289
231 715
CONN. INS290
231 715
CONN. INS290
X22
15 pin Dsub,
male
231 715
CONN. INS290
X24
15 pin Dsub,
male
231 715
CONN. INS290
X17
37 pin Dsub,
female
231 718
CONN. INS293
X32
37 pin Dsub,
female
231 718
CONN. INS293
X33
37 pin Dsub,
female
231 718
CONN. INS293
X30
ready-made cable
X31
9 pin Dsub,
male
INS425 for LWL cable INK416
with 6.0mm Ø or for connetions
internal to control enclosure
(plug-in connector with use of
ready-made LWL cable
IKO... not needed)
ready-made cable IKS 745/...
for programing and display unit
(max. length 30m)
231713
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
CONN. INS288
48
5. Order Informationen
Components
Conn.
strip
Name of
plug-in connector
Part
numer
Text
DRF 1.1
analog signal interface
X36
15 pin Dsub,
male
231 715
CONN. INS290
DBS 1.1
Interbus S Interface
X37
259 762
CONN. INS526
259 759
CONN. INS525
X25
9 pin Dsub,
female
9 pin Dsub,
male
plug-in conn. for LWL cable
X26
plug-in conn. for LWL cable
244 069
or
244 062
244 069
244 062
CONN. INS420
or
CONN. INS425
CONN. INS420
or
CONN. INS425
257 044
CONN. INS454
257 044
CONN. INS454
253 897
STECK-KL3,81 F
MC 1,5/ 2ST B 1-2
231 715
CONN. INS290
231 714
CONN. INS289
X38
CLC-D 1.1
cont. card
X27
X28
X29
DFF 1.1
Single-turn encoder
Interface
X18
X19
9 pin Dsub,
male
9 pin Dsub,
male
2 pin plug-in terminal
15 pin Dsub,
male
15 pin Dsub,
female
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
Comment
INS420 for LWL cable INK414
with 2.2mm Ø for control encl.
connetions internal
INS425 for LWL cable INK416
with 6.0mm Ø or for control encl.
connections internal
(plug-in conn. if ready-made
LWL cable is used
IKO... not needed)
49
5. Order Informationen
5.3. Item List
Pos.
Article
Selection
1.
Drive controller
DDC 1.2-.....-....-..
Selection data
1.1
Firmware FW . . .
Ask your
local
INDRAMATSales Rep.
1.2
Power connection
Ready-made cable IK. .../..
or
Connector INS ... and cable INK ... /..
3.4
1.3
Motor power cable
ready-made cable IK. .../..
or
cable INK ... /.. ; motor side
Connector INS ... and machine side
Connector INS ...
3.9
1.4
Connection to NC control
ready-made cable IKS 083/..
or connector INS 478 and cable INK 271
1.5
Motor feedback cable
ready-made cable IKS 374/..
or
cable INK 209/.. ; motor side
Connector INS 513 and machine side
Connector INS 290 ( Note: the connector
INS 290 is part of connector kit S..- DDS 2 )
2.0
Conneting accessories for
machine configuration
Ready-made cable
or
connector kit S..-DDS 2
Documentation for the
plug-in module
5.2
Transformer
3.2, 3.5, ..., 3.8
3.0
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
50
6.Index
6. Index
Symbole
15 inputs 9
16 outputs 9
A
Absolute encoder emulator 8
Accessories for Connections 47
Additional protective device 29
Advantage when replacing unit 9
Alphanumeric display 7
Ambient Conditions 11
ANALOG interface 8
Autotransformers 19
Autotransformers in IP 55 housing 19
Auxiliary Plug-In Cards 9
B
B6 switches 40
Basic unit 6
Bb contact 37
Bend radii of INDRAMAT cables
Bleeder Prewarning 37
Bleeder resistor 45
44
C
Cable for three-phase connections 18
Circuit breakers 7
Command Interface Card 8
Connected load 15
Connecting accessories 26
Connection voltage 15
Connector assignments for DSF and RSF
Conneting accessories 25
Continuous bleeder power 39
27
D
Data Sheet 11
DC bus converter 6
DC bus dynamic brake 36
DC bus dynamic braking 7
DDC 1.1 terminal diagram 13
DDC 1.2 6
DDC 1.2-N - dimensional data 41
DEA 32
DEA 5.1 9
DEA 6.1 9
DEF 1.1 9
Digital AC Drive 5
Digital servo feedback 27
DLC 1.1 8
DLC single-axis positioning module
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
32
51
6. Index
DLC single-axis postioning module 34
DLF 1.1 9
DLT Three-Phase Isolating Transformers
Drive controller configuration 6
Drive enable 30, 34
DSF 27
DSM 2.1 9
DSS 1.1 8
DSS 1.3 8
DST ... /G/ type transformers 19
DST Three-Phase Autotransformers 20
Duplication 9
Dynamic Braking 29, 30
21
E
E mode of installation 18, 24
E-stop 30, 34
E-Stop Relays 34
Electrical Connections 13
EN 60204 24
Exchanging binary signals 9
F
Fault Current Protective Device 40
Feedback Connection 27
FI current limiting circuit breakers 40
Frequency 15
Fuses 7
G
gL class fuses 17
Grounded threephase systems 16
Grounding the Supply System 16
H
High-resolution positioning interface
High-Voltage Testing 40
Holding brakes 23, 29, 32
Humidity 11
9
I
IKL 232 18
IKL 241 18
IKL 243 18
IKL 244 18
IKL 245 18
Increased ambient temperatures 12
Incremental encoder emulator 8
Incremental position interface 9
Individual cable parts 23
Individual IP 65 connectors 47
Inductance motors 29
INK 202 18
INK 203 18
INK 204 18
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
52
6. Index
INK 205 18
INK 206 18
INK 250 18
INK 391 39
Input/output interface 9
Inrush current limit 7
Installation above 1000 meters 12
Interface to NC Control Unit 28
IP 00 19
IP65 6
Isolating transformers 19
Isolation transformer 17
K
K1
K3
K4
30, 32, 34
30, 32, 34
30, 32, 34
M
Machine-dependent values 9
Mains Contactor 29
Maximum cable length 23, 27
Minimum Clearances 44
Motor power cable capacity 24
N
Non-periodic overvoltages
16
O
Operating Conditions 12
Operating principles 30
Operating software 9
Outputs AK1 and AK2 38
P
PC with a VT 100 emulation program 39
Permissible overvoltage levels 16
Positioning module 8
Power Connection Diameters and Fuses 17
Power Connections 43
Power OFF 36
Power ON 36
Power shutoff 7
Power supply cable 19
R
Radio interference transmission 23
Reading Drive Parameters 39
Ready state 37
Ready-made cables 23
Ready-made INDRAMAT cables 18
Regenerated Power 39
Resolver feedback 27
rf interference suppression 23
Rotary drive energy 39
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
53
6. Index
RS 232 Interface
RSF 27
39
S
Safety Clearances 45
SERCOS interface 8
SERCOS interface DSS card 8
Service life 44
Signal and Diagnostics Outputs 37
Signal path diagram 32
Signal Voltages 38
Slow-blow fuses 17
Soft start 36
Software Module 9
SSI standards 8
Standard software module 9
Supply line diameters 15
T
Technical Data 11
Terminal X4 27
Three-Phase Autotransformers
TN mains 16
Transformers 19
TT mains 16
Type Codes 46
22
U
U1 6
U5 6
UD contact 37
Ungrounded threephase systems
User-specific parameters 9
16
V
VT 100 terminal
39
X
X5
X7
X8
43
43
43
Z
Zero potential contact
37
• DOK-DIAX02-DDC01******-PRJ1-EN-E1,44 • 01.97
54
Indramat