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Rexroth Indramat DKC11.3-040-7 - User Manual

Rexroth Indramat DKC11.3-040-7
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Project Planning Manual
customerservice@hyperdynesystems.com | (479) 422-0390
SYSTEM200
ECODRIVE03
Drive Controllers

Table of Contents

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Summary

Project Planning Manual

1 Introduction to the System

Type Code for Drive Controller DKC

Explanation of the structure and fields of the DKC drive controller type code.

2 Important directions for use

2.1 Appropriate use

Guidelines for the correct and intended use of Rexroth Indramat products, emphasizing safety.

2.2 Inappropriate use

Definition and examples of inappropriate use, including environmental conditions.

3 Safety Instructions for Electric Drives and Controls

3.1 Introduction

Instructions to minimize risk of harm or damage, emphasizing reading all documentation before startup.

3.3 Hazards by Improper Use

Details specific hazards like high voltage, dangerous movements, hot surfaces, and improper handling.

3.5 Protection Against Contact with Electrical Parts

Safety measures and precautions when working with parts carrying voltages above 50 Volts.

3.6 Protection Against Electric Shock by Protective Low Voltage (PELV)

Guidelines for connecting equipment to terminals with voltages between 0 and 50 Volts, ensuring safe isolation.

3.7 Protection Against Dangerous Movements

Causes and prevention of dangerous movements due to faulty control or component malfunctions.

3.8 Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting

Health hazards and precautions for individuals with pacemakers, implants, or hearing aids near electrical equipment.

3.9 Protection Against Contact with Hot Parts

Warnings about hot housing surfaces and precautions to avoid burns.

3.10 Protection During Handling and Mounting

Safety measures for handling and mounting parts to prevent injuries from crushing or mechanical shock.

4 ECODRIVE03 DKC**.040, DKC**.100, DKC**.200

4.1 Technical Data

Technical specifications including dimensions for ECODRIVE03 DKC drive controllers.

Electric Data of the Individual DKC**.3 Components

Table detailing electric data for DKC**.3-040-7-FW and DKC**.3-100-7-FW mains connections and power sections.

4.2 Electrical connections - independent of the drive controller type

Total connection diagram for DKC**.3 drive controllers, showing pin assignments.

RS485 interface

Details on using the RS485 interface for serial bus communication and PC connection.

X11, DC bus dynamic brake (ZKS), U D power supply

Technical description of the X11 connector for DC bus dynamic brake and UD power supply.

XE1, XE2 Protective conductor connections for motor and mains

Technical description of XE1 and XE2 connectors for protective conductor connections.

4.3 Electrical Connections - dependent on the drive controller type

Technical description and connection diagram for the Parallel Interface of DKC 01.3 drive controllers.

DKC 02.3-***-7-FW - SERCOS interface

View of the command communication interface and connection diagram for the SERCOS interface.

DKC 03.3-***-7-FW - Probus-DP Interface

View of the command communication interface and technical description of the Probus-DP connector.

DKC 04.3-***-7-FW - InterBus Interface

View of the command communication interface and technical description of the InterBus connectors.

DKC 05.3-***-7-FW - CANopen Interface

View of the command communication interface and technical description of the CANopen connector.

DKC 06.3-***-7-FW - DeviceNet Interface

View of the command communication interface and technical description of the DeviceNet connector.

DKC 11.3-***-7-FW - Analog Interface

View of the command communication interface for the Analog Interface.

DKC 21.3-***-7-FW - Parallel Interface 2

View of the command communication interface for Parallel Interface 2.

DKC 22.3-***-7-FW - SERCOS interface

View of the command communication interface and connection diagram for the SERCOS interface 2.

5 ECODRIVE03 DKC**.3-016

5.2 Electrical connections

Total connection diagram for DKC**.3-016 drive controller, showing pin assignments.

RS232 interface

Details on using the RS232 interface for programming and diagnosis on DKC**.3-016.

X5, Motor and Mains Connections

Technical description of the X5 connector for motor and mains connections on DKC**.3-016.

Motor connection

Information on connecting motors for DKC**.3-016, including cable lengths and EMC.

Holding brake (BR+, BR-)

Loadability and connection details for holding brakes on DKC**.3-016.

6 ECODRIVE03 Auxiliary Bleeder Module BZM01.3

Complete Terminal Diagram

Complete terminal diagram for the BZM01.3 module, showing all connections and pin designations.

X2, DC bus dynamic brake (ZKS), Diagnostic Signals

Technical description of the X2 connector for DC bus dynamic brake and diagnostic signals.

X5, DC bus and Mains connection

Technical description of the X5 connector for DC bus and mains connections.

Mains connections

Diagrams for single-phase and three-phase mains connections.

7 ECODRIVE03 Auxiliary Capacitance Module CZM01.3

9 DC24 V NTM power supplies

9.5 Electrical connection

Guidance on connecting the NTM power supply to a line filter, including notes on sensor inputs.

10 DST transformers

11 Mains Connections

11.2 The Ground Conditions of the Power Supply Network

Information on grounded and ungrounded networks, overvoltage protection, and required voltage limits.

11.4 Control Circuits for the Mains Connection

Explanation of control circuits for mains connection, including Bb contact and recommended protective circuits.

Control Circuits with E-Stop

Guidelines for using the E-stop function to activate drive-internal error reactions and its implications.

Control Circuits with internal DC bus dynamic brake (ZKS)

Explanation of the internal DC bus dynamic brake (ZKS) usage and its limitations regarding personnel safety.

11.5 Mains Contactor; Fuses

Guidance on selecting mains contactors and fuses, including computing phase current and connected load.

Q1 Fuse and K1 Contactor

Selecting table for Q1 fuses and K1 contactors, including current, cross-sections, and delays.

12 Constructing the Control Cabinet

Determining power dissipation

Methods for determining power dissipation based on current load and regenerated power.

12.2 Using Cooling Units in the Control Cabinet

Guidelines for using cooling units, emphasizing temperature settings and avoiding condensation.

14 Identifying the Components

15 Replacing or Exchanging Drive Components

15.1 General

General information on using the diagnostic display for problem search and returning defective units.

15.2 Procedure on Replacing the Unit

Step-by-step procedure for replacing the drive controller, including safety precautions.

Replacing the Motor

Procedure for replacing the motor, including safety notes and reference to machine manufacturer instructions.

Replacing cables

Procedure for replacing cables, emphasizing safety and checking cable compatibility.

Fault Report

Fault report template for diagnosing problems and their causes, intended for Rexroth Indramat service.

15.3 Replacing Firmware (DKC**.3-040;100;200-7-FW)

Procedure for replacing the parameter module, including securing parameters and opening the lock.

Replacing the Firmware Module

Step-by-step procedure for replacing the firmware module, including software and hardware steps.

Replacing the Programming Module (complete module)

Procedure for replacing the complete programming module, including parameter backup and software loading.

15.4 Replacing Firmware (DKC**.3-016-7-FW)

Procedure for replacing firmware for DKC**.3-016, including parameter securing and using DOLFI software.

16 Attachment

16.1 Sizing relevant to supply and regeneration

Conditions relevant to supply and regeneration for sizing the drive, including energy flux.

Calculations with regard to the power and energy allowed on the device side

Formulas and definitions for calculating allowed power and energy on the device side.

Calculations with regard to the power and energy resulting on the installation side

Formulas and definitions for calculating power and energy resulting on the installation side.

Calculating the allowed continuous braking resistor and DC bus power

Methods for calculating allowed continuous braking resistor and DC bus power for multiple connected units.

16.3 Control Cabinet Construction with Recommendations for EMC and Cooling

Recommendations for control cabinet construction focusing on EMC and cooling strategies.

16.5 What is needed to prepare to start-up

List of necessary equipment and software prerequisites for starting up an ECODRIVE drive system.

18 Service & Support

18.1 Helpdesk

Contact information and service hours for the Rexroth Indramat Helpdesk.

18.2 Service-Hotline

Contact details for direct service support outside of Helpdesk hours.

Summary

Project Planning Manual

1 Introduction to the System

Type Code for Drive Controller DKC

Explanation of the structure and fields of the DKC drive controller type code.

2 Important directions for use

2.1 Appropriate use

Guidelines for the correct and intended use of Rexroth Indramat products, emphasizing safety.

2.2 Inappropriate use

Definition and examples of inappropriate use, including environmental conditions.

3 Safety Instructions for Electric Drives and Controls

3.1 Introduction

Instructions to minimize risk of harm or damage, emphasizing reading all documentation before startup.

3.3 Hazards by Improper Use

Details specific hazards like high voltage, dangerous movements, hot surfaces, and improper handling.

3.5 Protection Against Contact with Electrical Parts

Safety measures and precautions when working with parts carrying voltages above 50 Volts.

3.6 Protection Against Electric Shock by Protective Low Voltage (PELV)

Guidelines for connecting equipment to terminals with voltages between 0 and 50 Volts, ensuring safe isolation.

3.7 Protection Against Dangerous Movements

Causes and prevention of dangerous movements due to faulty control or component malfunctions.

3.8 Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting

Health hazards and precautions for individuals with pacemakers, implants, or hearing aids near electrical equipment.

3.9 Protection Against Contact with Hot Parts

Warnings about hot housing surfaces and precautions to avoid burns.

3.10 Protection During Handling and Mounting

Safety measures for handling and mounting parts to prevent injuries from crushing or mechanical shock.

4 ECODRIVE03 DKC**.040, DKC**.100, DKC**.200

4.1 Technical Data

Technical specifications including dimensions for ECODRIVE03 DKC drive controllers.

Electric Data of the Individual DKC**.3 Components

Table detailing electric data for DKC**.3-040-7-FW and DKC**.3-100-7-FW mains connections and power sections.

4.2 Electrical connections - independent of the drive controller type

Total connection diagram for DKC**.3 drive controllers, showing pin assignments.

RS485 interface

Details on using the RS485 interface for serial bus communication and PC connection.

X11, DC bus dynamic brake (ZKS), U D power supply

Technical description of the X11 connector for DC bus dynamic brake and UD power supply.

XE1, XE2 Protective conductor connections for motor and mains

Technical description of XE1 and XE2 connectors for protective conductor connections.

4.3 Electrical Connections - dependent on the drive controller type

Technical description and connection diagram for the Parallel Interface of DKC 01.3 drive controllers.

DKC 02.3-***-7-FW - SERCOS interface

View of the command communication interface and connection diagram for the SERCOS interface.

DKC 03.3-***-7-FW - Probus-DP Interface

View of the command communication interface and technical description of the Probus-DP connector.

DKC 04.3-***-7-FW - InterBus Interface

View of the command communication interface and technical description of the InterBus connectors.

DKC 05.3-***-7-FW - CANopen Interface

View of the command communication interface and technical description of the CANopen connector.

DKC 06.3-***-7-FW - DeviceNet Interface

View of the command communication interface and technical description of the DeviceNet connector.

DKC 11.3-***-7-FW - Analog Interface

View of the command communication interface for the Analog Interface.

DKC 21.3-***-7-FW - Parallel Interface 2

View of the command communication interface for Parallel Interface 2.

DKC 22.3-***-7-FW - SERCOS interface

View of the command communication interface and connection diagram for the SERCOS interface 2.

5 ECODRIVE03 DKC**.3-016

5.2 Electrical connections

Total connection diagram for DKC**.3-016 drive controller, showing pin assignments.

RS232 interface

Details on using the RS232 interface for programming and diagnosis on DKC**.3-016.

X5, Motor and Mains Connections

Technical description of the X5 connector for motor and mains connections on DKC**.3-016.

Motor connection

Information on connecting motors for DKC**.3-016, including cable lengths and EMC.

Holding brake (BR+, BR-)

Loadability and connection details for holding brakes on DKC**.3-016.

6 ECODRIVE03 Auxiliary Bleeder Module BZM01.3

Complete Terminal Diagram

Complete terminal diagram for the BZM01.3 module, showing all connections and pin designations.

X2, DC bus dynamic brake (ZKS), Diagnostic Signals

Technical description of the X2 connector for DC bus dynamic brake and diagnostic signals.

X5, DC bus and Mains connection

Technical description of the X5 connector for DC bus and mains connections.

Mains connections

Diagrams for single-phase and three-phase mains connections.

7 ECODRIVE03 Auxiliary Capacitance Module CZM01.3

9 DC24 V NTM power supplies

9.5 Electrical connection

Guidance on connecting the NTM power supply to a line filter, including notes on sensor inputs.

10 DST transformers

11 Mains Connections

11.2 The Ground Conditions of the Power Supply Network

Information on grounded and ungrounded networks, overvoltage protection, and required voltage limits.

11.4 Control Circuits for the Mains Connection

Explanation of control circuits for mains connection, including Bb contact and recommended protective circuits.

Control Circuits with E-Stop

Guidelines for using the E-stop function to activate drive-internal error reactions and its implications.

Control Circuits with internal DC bus dynamic brake (ZKS)

Explanation of the internal DC bus dynamic brake (ZKS) usage and its limitations regarding personnel safety.

11.5 Mains Contactor; Fuses

Guidance on selecting mains contactors and fuses, including computing phase current and connected load.

Q1 Fuse and K1 Contactor

Selecting table for Q1 fuses and K1 contactors, including current, cross-sections, and delays.

12 Constructing the Control Cabinet

Determining power dissipation

Methods for determining power dissipation based on current load and regenerated power.

12.2 Using Cooling Units in the Control Cabinet

Guidelines for using cooling units, emphasizing temperature settings and avoiding condensation.

14 Identifying the Components

15 Replacing or Exchanging Drive Components

15.1 General

General information on using the diagnostic display for problem search and returning defective units.

15.2 Procedure on Replacing the Unit

Step-by-step procedure for replacing the drive controller, including safety precautions.

Replacing the Motor

Procedure for replacing the motor, including safety notes and reference to machine manufacturer instructions.

Replacing cables

Procedure for replacing cables, emphasizing safety and checking cable compatibility.

Fault Report

Fault report template for diagnosing problems and their causes, intended for Rexroth Indramat service.

15.3 Replacing Firmware (DKC**.3-040;100;200-7-FW)

Procedure for replacing the parameter module, including securing parameters and opening the lock.

Replacing the Firmware Module

Step-by-step procedure for replacing the firmware module, including software and hardware steps.

Replacing the Programming Module (complete module)

Procedure for replacing the complete programming module, including parameter backup and software loading.

15.4 Replacing Firmware (DKC**.3-016-7-FW)

Procedure for replacing firmware for DKC**.3-016, including parameter securing and using DOLFI software.

16 Attachment

16.1 Sizing relevant to supply and regeneration

Conditions relevant to supply and regeneration for sizing the drive, including energy flux.

Calculations with regard to the power and energy allowed on the device side

Formulas and definitions for calculating allowed power and energy on the device side.

Calculations with regard to the power and energy resulting on the installation side

Formulas and definitions for calculating power and energy resulting on the installation side.

Calculating the allowed continuous braking resistor and DC bus power

Methods for calculating allowed continuous braking resistor and DC bus power for multiple connected units.

16.3 Control Cabinet Construction with Recommendations for EMC and Cooling

Recommendations for control cabinet construction focusing on EMC and cooling strategies.

16.5 What is needed to prepare to start-up

List of necessary equipment and software prerequisites for starting up an ECODRIVE drive system.

18 Service & Support

18.1 Helpdesk

Contact information and service hours for the Rexroth Indramat Helpdesk.

18.2 Service-Hotline

Contact details for direct service support outside of Helpdesk hours.

Rexroth Indramat DKC11.3-040-7 Specifications

General IconGeneral
BrandRexroth Indramat
ModelDKC11.3-040-7
CategoryController
LanguageEnglish

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