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1-14 Introduction and Overview

1.5

VisualMotion 6.0

CLC-D Overview

CLC-D02.3M hardware

Figure 1-9: CLC-D02.3M Hardware

CLC-D Serial Communication
Port A (X27) is configured to respond to the VisualMotion ASCII Host
Protocol. Port B (X28) can be configured to respond to Host Protocol, BTC06
or another interface. Both ports always operate with:
• 8 bits per character
• 1 stop bit
• no parity.

Serial Com Options

Baud Rate

Checksum

Port Mode

Protocol

Port A (X27) default

9600

enabled

RS-232

Host Protocol

Port A (X27) valid settings

300, 1200, 2400,
4800, 9600,
19200, 38400

enabled or
disabled

RS-232,422,485

Host Protocol

Port B (X28) default

9600

enabled

RS-232

Host Protocol

Port B (X28) valid settings

300, 1200, 2400,
4800, 9600

enabled or
disabled

RS-232,422,485

Off, Host Protocol,
BTC06

Table 1-1: CLC-D configurable communication settings

DOK-VISMOT-VM*-06VRS**-WA02-AE-P •03/99

Introduction and Overview 1-15

VisualMotion 6.0

CLC-D Jumper Configuration
Jumpers S1 and S2 set the default configuration for serial ports X27 and X28
respectively. If the jumper is installed, the port is configured for the default
settings of RS-232 and 9600 baud.

Figure 1-10: CLC-D jumper configuration

CLC-D SERCOS
The SERCOS port is used for loop-through, daisy-chained installation into a
SERCOS fiber-optic ring. The output port, Tx, is connected to the SERCOS
input port, Rx, of the next SERCOS device in the ring. Each SERCOS device
is interconnected, output to input, with the output of the last device returned to
the SERCOS input, Rx, of the CLC-D.

Figure 1-11: Fiber optic ring structure

DOK-VISMOT-VM*-06VRS**-WA02-AE-P •03/99

1-16 Introduction and Overview

VisualMotion 6.0

On-Board Battery
This battery provides backup power for the CLC onboard SRAM when control
voltage is not applied. The battery's power level is checked every time the
CLC is powered up or during initialization from parameter mode to provide
advanced warning of impending failure. A diagnostic message is displayed
(E206 Battery is low: replace it soon) when the level falls below 10% of
remaining capacity. Based on the lifespan table below, this could translate
into less then a month before failure at 45 °C (113 °F.) It is vital for action to
be taken when a Battery is low warning is issued.


Secure a complete archive of the VisualMotion system data



Order a new 3-volt Lithium button-style battery, CR2477N (MnO2/Li).



Indramat material number: 254284



Recommended actions:

Replace battery as soon as possible.

To prevent undue losses, a Preventive Maintenance Program should be
put into place that does not rely on the batteries power level check to
determine replacement period. The following lifespan table contains some
general guidelines that can be used to devise an appropriate schedule.
Battery lifespan

Ambient
temperature

3-shift
operations

2-shift
operations

1-shift
operation

Storage

25 °C (77 °F)

4 years

4 years

4 years

3 years

35 °C (95 °F)

4 years

3 years

2 years

1.5 years

45 °C (113 °F)

3 years

2 years

1.2 years

9 months

Table 1-2: Battery lifespan

Warning

Loss of VisualMotion System
Failure to replace can result in lost parameters.
⇒ The following is a list of items that will be lost if the battery
fails and is not replaced.
• CLC System parameters C-0-xxxx
• Axis parameters A-0-xxxx
• Task parameters
• CLC Cam tables, PLS and PID data
• Events, I/O Mapper, FieldBus Mapper
• Points tables, Variables, Zones
• Downloaded VisualMotion programs

Note:

The battery is generally drained after this period and must be
replaced.

DOK-VISMOT-VM*-06VRS**-WA02-AE-P •03/99

Introduction and Overview 1-17

VisualMotion 6.0

Replacing the battery

Once the battery is removed, any parameters stored in SRAM memory are
retained for only one minute. Replace the battery within this minute.
Procedure:
1. Remove the battery from its packaging and have it close at hand for
installation
2. Before replacing the battery, archive the system using VisualMotion
Toolkit. Refer to Chapter 2, The File Menu - Archive.
3. Switch power off to the system containing the CLC card
4. Remove CLC card from the system

Caution

Electro-static discharge
Sensitive electronic device
⇒ The CLC card is a sensitive electronic device, use caution
when handling this board. Do not expose to Electro-static
discharge or place the board directly on a conductive
surface. Only handle the board by its face-plate or card
edges.

5. Remove old battery by sliding it out of it's holder
6. Insert the new battery into holder (no more than one minute later)
7. Write the month and year on the battery's end cap for future reference.
(This information should also be written on a label and place in close
proximity to the CLC for easier observation)

CLC-D02.3 Front Panel Diagnostic Display
7-Segment display
The CLC-D has a 7-Segment LED display (H4).
operating and error conditions of the card.

H4

7-Segment
Display
CLC
Watchdog

Figure 1-12: 7-segment display on the CLC-D

DOK-VISMOT-VM*-06VRS**-WA02-AE-P •03/99

It displays the current

1-18 Introduction and Overview

Normal operations

VisualMotion 6.0

In normal operating conditions, a static display shows the current mode of the
CLC.
H4 Display

Status
Initial display
Initialization Mode, SERCOS phases 1-4
Parameter mode
No user tasks are running (Halt)
Task A is running
Task B is running
Task C is running
Task D is running

Table 1-3: Normal operating conditions

Error codes

When an error exists, the CLC-D displays an " E " , indicating error, followed by
a three digit diagnostic code. To the viewer, the display appears to be
blinking. The following figure illustrates the chronological sequence for
emergency stop condition, E400.

1000ms

500ms

500ms

500ms

Figure 1-13: Example of an E400, Emergency Stop, error code

Code

Error Type

E200 - E399

Warning

E400 - E999

Shutdown Error

Refer to Chapter 3, Monitoring and Diagnostics, for a complete listing of the
available three digit Warning and Shutdown error codes.
System Watchdog
The decimal point on the display is connected to a hardware watchdog circuit
that is refreshed by the CLC every 100ms. If the microprocessor fails or if the
CLC drops into the pROBE monitor, the display is blanked and the decimal
point turns on. While the CLC is running, the decimal point is off.

H4

7-Segment Display
(OFF)
CLC Watchdog
(On)

Figure 1-14: Watchdog message on the CLC

DOK-VISMOT-VM*-06VRS**-WA02-AE-P •03/99

Introduction and Overview 1-19

VisualMotion 6.0

1.6

CLC-P01.1 Overview

CLC-P01.1 hardware

Figure 1-15: CLC-P01.1 Hardware

CLC-P Serial Communication
Port A (X27) is configured to respond to the VisualMotion ASCII Host
Protocol. Port B (X28) can be configured to respond to Host Protocol, BTC06
or another interface. Both ports always operate with:
• 8 bits per character
• 1 stop bit
• no parity
For configurable communication settings, refer to Table 1-1 on page 1-14

DOK-VISMOT-VM*-06VRS**-WA02-AE-P •03/99

1-20 Introduction and Overview

VisualMotion 6.0

CLC-P01.1 Jumper Configuration
Jumpers S1 and S2 set the default configuration for serial ports X27 and X28
respectively. If the jumper is installed, the port is configured for the default
settings of RS-232 and 9600 baud.

Figure 1-16: CLC-P01.1 jumper location

Jumpers S5 through S7 set the PC interrupt. Only IRQ2 (default) can be
used.
PC Interrupt

S5

S6

S7

IRQ2 (IRQ9)

In

Out

Out

IRQ3

Out

In

Out

IRQ5

Out

Out

In

Table 1-4: CLC-P01.1 IRQ settings

DOK-VISMOT-VM*-06VRS**-WA02-AE-P •03/99

Introduction and Overview 1-21

VisualMotion 6.0

Jumpers S8 through S11 set the base address of a 16K memory segment in
the Host’s RAM. This memory space is used to exchange information
between the CLC and the Host.
Card Number

Base
Address

S11

S10

S9

S8

0

C000

In

In

In

1

C400

In

In

In

Out

2

C800

In

In

Out

In

3

CC00

In

In

Out

Out

4

D000

In

Out

In

In

5

D400

In

Out

In

Out

In

6

D800

In

Out

Out

In

7

DC00

In

Out

Out

Out

8

E000

Out

In

In

In

9

E400

Out

In

In

Out

10

E800

Out

In

Out

In

11

EC00

Out

In

Out

Out

12

F000

Out

Out

In

In

13

F400

Out

Out

In

Out

14

F800

Out

Out

Out

In

15

FC00

Out

Out

Out

Out

Table 1-5: CLC-P base address jumper settings

On-Board Battery
This battery provides backup power for the CLC onboard SRAM when control
voltage is not applied. The battery's power level is checked every time the
CLC is powered up or during initialization from parameter mode to provide
advanced warning of impending failure. A diagnostic message is displayed
(206 Battery is low: replace it soon) when the level falls below 10% of
remaining capacity. Based on the lifespan table on page 1-16, this could
translate into less then a month before failure at 45 °C (113 °F.) It is vital for
action to be taken when a Battery is low warning is issued.


Secure a complete archive of the VisualMotion system data



Order a new 3-volt Lithium button-style battery, CR2477N (MnO2/Li).



Indramat material number: 254284



Recommended actions:

Replace battery as soon as possible.

For complete details on battery lifespan and replacement, refer to On-Board
Battery on page 1-16.

CLC-P SERCOS
The SERCOS port is used for loop-through, daisy-chained installation into a
SERCOS fiber-optic ring. The output port, Tx, is connected to the SERCOS
input port, Rx, of the next SERCOS device in the ring. Each SERCOS device
is interconnected, output to input, with the output of the last device returned to

DOK-VISMOT-VM*-06VRS**-WA02-AE-P •03/99

1-22 Introduction and Overview

VisualMotion 6.0

the SERCOS input, Rx, of the CLC-P. See Figure 1-11: Fiber optic ring
structure on page 1-15 for an illustration.

Viewing Error codes using VisualMotion's CLC DDE Server
Physically viewing diagnostic messages on the CLC-P hardware is not
possible. Unlike the CLC-D card, which has a visible 7-Segment display (H4)
for viewing error codes, the CLC-P does not have a visible display. The
design of the CLC-P does not require for it to have a visible means of viewing
errors. This card is generally installed in a personal computer and for this
reason is normally not visible.
The monitoring and communications of error codes are handle by means of
the CLC DDE Server. This Windows based Dynamic Data Exchange (DDE)
Server application is used to communicate with Indramat's CLC motion
control cards. Unlike the CLC-D which begins an error code with the letter
" E " , the DDE Server represents an error code with it's respective three digit
number followed by the error's description. For example, an Emergency Stop
error on CLC-D would appears as a alternating blinking " E400 " , while on the
DDE Server it would simply appear as " 400 EMERGENCY STOP. "

Figure 1-17: CLC DDE Server

In order to view diagnostic messages on the DDE Server, the " CLC Status
Display " must be set to SERIAL_0. This is accomplished by selecting
Settings ⇒ Server Configuration from the CLC DDE Server's main menu.
Refer to Chapter 4, CLC DDE Server for more information.

DOK-VISMOT-VM*-06VRS**-WA02-AE-P •03/99

Introduction and Overview 1-23

VisualMotion 6.0

Figure 1-18: Setting SERIAL_0 for CLC Status Display - DDE Server

Viewing Error codes using VisualMotion Toolkit
To view error codes using VisualMotion, simply select the following menu
selection:

Status ⇒ System from VisualMotion's main menu and the following screen
appears.

Figure 1-19: Viewing error codes using VisualMotion

DOK-VISMOT-VM*-06VRS**-WA02-AE-P •03/99

1-24 Introduction and Overview

1.7

VisualMotion 6.0

CLC-P02 Overview
The CLC-P02 is a motion control on the PC/104 platform. The VisualMotion
firmware on this platform includes all of the features of the CLC-P01, with
improvements in the configuration and memory capacity.

CLC-P02.2 hardware

Figure 1-20: CLC-P02.2 Hardware

CLC-P02 Serial Communication
Port A (X27) is configured to respond to the VisualMotion ASCII Host
Protocol. Port B (X28) can be configured to respond to Host Protocol, BTC06
or another interface. Both ports always operate with:
• 8 bits per character
• 1 stop bit
• no parity

DOK-VISMOT-VM*-06VRS**-WA02-AE-P •03/99

Introduction and Overview 1-25

VisualMotion 6.0

Serial Com Options

Baud Rate

Checksum

Port Mode

Protocol

Port A (X27) default

9600

enabled

RS-232

Host Protocol

Port A (X27) valid settings

300, 1200, 2400,
4800, 9600,
19200, 38400

enabled or
disabled

RS-232,422,485

Host Protocol

Port B (X28) default

9600

enabled

RS-232

Host Protocol

Port B (X28) valid settings

300, 1200, 2400,
4800, 9600

enabled or
disabled

RS-232,422,485

Off, Host Protocol,
BTC06

Table 1-6: CLC-P02 configurable communication settings

CLC-P02 Jumper Configuration
Jumpers I5 and I6 set the default configuration for serial ports X27 and X28
respectively. If the jumper is installed, the port is configured for the default
settings of RS-232 and 9600 baud.

Figure 1-21: CLC-P02 jumper configuration

DOK-VISMOT-VM*-06VRS**-WA02-AE-P •03/99

1-26 Introduction and Overview

PC/104 Memory Address
Selection

VisualMotion 6.0

Switches 1 through 4 set the base address of a 1MB memory segment in the
Host's RAM. This memory space is used to exchange information between
the CLC and the Host.
Card
Number

Base
Address

1

2

3

4

0

D000:0000

OFF

ON

ON

ON

1

D000:2000

OFF

ON

ON

OFF

2

D000:4000

OFF

ON

OFF

ON

3

D000:6000

OFF

ON

OFF

OFF

4

D000:8000

OFF

OFF

ON

ON

5

D000:A000

OFF

OFF

ON

OFF

6

D000:C000

OFF

OFF

OFF

ON

7

D000:E000

OFF

OFF

OFF

OFF

8

E000:0000

ON

ON

ON

ON

9

E000:2000

ON

ON

ON

OFF

10

E000:4000

ON

ON

OFF

ON

11

E000:6000

ON

ON

OFF

OFF

12

E000:8000

ON

OFF

ON

ON

13

E000:A000

ON

OFF

ON

OFF

14

E000:C000

ON

OFF

OFF

ON

15

E000:E000

ON

OFF

OFF

OFF

Table 1-7: CLC-P02 base address switch settings
PC/104 Interrupt Selection

Switches 5 through 8 on the S1 DIP switch, selects the interrupt line for the
CLC to PC interrupt.
Note:

Only one of these switches can be on at a time, or there will be an
interrupt conflict.

PC Interrupt

5

6

7

8

IRQ10

OFF

OFF

OFF

ON

IRQ11

OFF

OFF

ON

OFF

IRQ12

OFF

ON

OFF

OFF

IRQ15

ON

OFF

OFF

OFF

None

OFF

OFF

OFF

OFF

Table 1-8: CLC-P02 IRQ settings

DOK-VISMOT-VM*-06VRS**-WA02-AE-P •03/99

Introduction and Overview 1-27

VisualMotion 6.0

CLC-P02 On-Board Backup Power (Accumulator)
The backup power device on the CLC-P02 is not a battery, but an
accumulator which provides power to the onboard SRAM when control
voltage is not applied.
Note:

A defective accumulator cannot be replaced by the customer.
Since the accumulator is soldered to the board, the card must be
returned to INDRAMAT for maintenance repair.

A fully charged accumulator will provide approximately 6 months of SRAM
buffering at an ambient temperature of 25 °C (77 °F) if the card is not in
operation.
At 45 °C (113 °F), the accumulator backup power will last approximately 3
months.
If the accumulator is completely discharged, it will require approximately 50
hours of online power to fully charge.
Note:

Charge time:
1 hour of recharging will provide about 100 hours of buffering at 25
°C (77 °F.)
Lifetime Expectancy:
The lifetime expectancy of the accumulator on a CLC-P02 card
that is powered for 8 hours and off for 16 hours is at least 7 - 10
years.

A diagnostic message is displayed (206 Battery is low: replace it soon)
when the level falls below 10% of the remaining capacity. Diagnostic
messages can be viewed by selecting Status ⇒ System from VisualMotion
Toolkits' main menu. The diagnostic message field within the System
Parameters window is read from CLC card parameter C-0-0122.
Note:

Recommended actions:

A " 206 Battery is low: replace it soon " error does not
necessarily mean that the accumulator is defective. Unlike
batteries, accumulators can be re-charged by applying and
maintaining power for a few days. If the error returns after the
re-charging period, and power is still applied to the system, send
the card in to INDRAMAT for repairs.

• Secure a complete archive of the VisualMotion system data
• Re-charge the accumulator by powering the card for a few days
• If error persist, return the card to INDRAMAT for repairs

CLC-P SERCOS
The SERCOS port is used for loop-through, daisy-chained installation into a
SERCOS fiber-optic ring. The output port, Tx, is connected to the SERCOS
input port, Rx, of the next SERCOS device in the ring. Each SERCOS device
is interconnected, output to input, with the output of the last device returned to
the SERCOS input, Rx, of the CLC-P. See Figure 1-11: Fiber optic ring
structure on page 1-15 for an illustration.

DOK-VISMOT-VM*-06VRS**-WA02-AE-P •03/99

1-28 Introduction and Overview

1.8

VisualMotion 6.0

CLC-V Overview

CLC-V02.3 hardware

Figure 1-22: CLC-V02.3 Hardware

CLC-V Serial Communication
Port A (X27) is configured to respond to the VisualMotion ASCII Host
Protocol. Port B (X28) can be configured to respond to Host Protocol, BTC06
or another interface. The serial interface is compatible with EIA RS-232C and
supports signals for both AT and XT type Host PCs. Both ports always
operate with:
• 9600 baud
• 8 bits per character
• 1 stop bit
• no parity.

DOK-VISMOT-VM*-06VRS**-WA02-AE-P •03/99

Introduction and Overview 1-29

VisualMotion 6.0

For configurable communication settings, refer to Table 1-1 on page 1-14

CLC-V SERCOS
The SERCOS port is used for loop-through, daisy-chained installation into a
SERCOS fiber-optic ring. The output port, Tx, is connected to the SERCOS
input port, Rx, of the next SERCOS device in the ring. Each SERCOS device
is interconnected, output to input, with the output of the last device returned to
the SERCOS input, Rx, of the CLC-V. See Figure 1-11: Fiber optic ring
structure on page 1-15 for an illustration.

CLC-V Configuration Switches

Slide Switch SW5 (Default)
OFF

ON

1
2
3
4
5
6
7
8

SW5

+
B

Math Coprocessor / Flash Mezzanine
EPROM

A

Opto Isolated I/O
Drivers

SERCOS MODULE

SERCOS
ASIC

J1
J2
Slide Switch SW6 (Default)

+
SW6

OFF

ON
1
2

Figure 1-23: CLC-V Configuration Switches

DOK-VISMOT-VM*-06VRS**-WA02-AE-P •03/99

1-30 Introduction and Overview

VisualMotion 6.0

Configuration Switch - SW5
SW5 Position

Default

1

ON

2

OFF

3

OFF

Function
ON - Programming of the local Flash EPROM
enabled
OFF - Local Flash EPROM write protected
ON - CLC-V Drives VME SYSRESET
OFF - SYSRESET not driven
ON - CLC-V Accepts SYSRESET from VME
OFF - SYSRESET not received

4

ON

ON - Power-fail reset voltage set to 4.8V
OFF - Power-fail reset voltage set to 4.2V

5

ON

ON - Programming of Flash EPROM enabled
OFF - Flash EPROM write protected
6 & 7 Select the CLC's VME Bus request level:
BR0

6
7

ON

BR2

BR3

OFF

ON

ON

OFF

ON

8

BR1

OFF

ON

ON

OFF

ON

ON - VME Slot 1 functions enabled
OFF - VME Slot 1 functions disabled

Table 1-9: Configuration switch - SW5

Configuration Switch - SW6
Both switches SW6-1 and SW6-2 are functionally used as one switch. Both
must have the same setting, ON or OFF.
SW6 Position

Setting

1

OFF
(default)

2

OFF
(default)
1

ON

2

ON

Function
Disables the CLC-V's on-board secondary
battery. Backup battery is provided through
the VME bus STDBY line.
Enables the CLC-V's on-board secondary
battery and disconnects the CLC-V from the
VME bus STDBY line. Both positions of
SW6 must be ON to enable the on-board
secondary battery and disconnect the CLC-V
from the VME bus STDBY line.

CAUTION: Leave both switch positions OFF, as set by the factory. The VME
card cage is the required source of battery back-up. Damage to the CLC-V's
on-board secondary battery may occur if a VME card cage supplies battery
backup and either position of SW6 is set ON.

Table 1-10: Configuration switch - SW6

On-Board Battery
This battery provides backup power for the CLC onboard SRAM and the real
time clock (RTC) when control voltage is not applied. The battery's power
level is checked every time the CLC is powered up or during initialization from
parameter mode to provide advanced warning of impending failure. A
diagnostic message is displayed (206 Battery is low: replace it soon) when
the level falls below 10% of remaining capacity. It is vital for action to be taken
when a Battery is low warning is issued.

DOK-VISMOT-VM*-06VRS**-WA02-AE-P •03/99

Introduction and Overview 1-31

VisualMotion 6.0



Secure a complete archive of the VisualMotion system data



Order a new 3-volt Lithium button-style battery, CR2032 (MnO2/Li).



Indramat material number: 600482



Recommended actions:

Replace battery as soon as possible.

DOK-VISMOT-VM*-06VRS**-WA02-AE-P •03/99

1-32 Introduction and Overview

VisualMotion 6.0

DOK-VISMOT-VM*-06VRS**-WA02-AE-P •03/99

Using VisualMotion Toolkit for diagnosing 2-1

VisualMotion 6.0

2

Using VisualMotion Toolkit for diagnosing

2.1

VisualMotion Toolkit 6
VisualMotion Toolkit 6 (VMT) is Indramat's Windows ™ based development
environment for programming the VisualMotion Controller (VMC) cards.
Along with VMT's programming capabilities, it can also be used to help
diagnose system, drive and card diagnostics.
Note:

This chapter is intended to help trained operating and
maintenance personnel diagnose error codes using VisualMotion
Toolkit. For a complete description of VisualMotion Toolkit, please
refer to the following documentation.

• VisualMotion GPS 6.0, Start Up Guide
• DOK-VISMOT-VM*06VRS**-PRJ1-AE-P, Material No. 282762
• VisualMotion GPS 6.0, Reference Manual
• DOK-VISMOT-VM*06VRS**-FKB1-AE-P, Material No. 280585

2.2

VisualMotion to PC connection
To establish communications between the VisualMotion CLC-D cards and a
PC, use the IKS0061 standard RS-232 serial communication cable. For the
CLC-V, use the IKS0110 standard RS-232 serial communication cable.

.
Figure 2-1: VisualMotion to PC connection diagram

Once the hardware connections have been made, use the following
procedure to confirm communications.

DOK-VISMOT-VM*-06VRS**-WA02-AE-P • 03/99

2-2 Using VisualMotion Toolkit for diagnosing

VisualMotion 6.0

⇒ Connect communication cable between CLC port X28 and the PC's com
port.
⇒ Power-up VisualMotion System (drives, CLC cards, motors, etc.)
⇒ Open VisualMotion Toolkit windows program (Refer to the VisualMotion
Start-up Guide for installation instructions)
⇒ From the VisualMotion Toolkit main menu, select Status ⇒ System. If
the System Parameters screen loads with information, communications
have been established.
The user is now ready to use VisualMotion Toolkit.

2.3

The File menu
The file menu allows the user to perform standard windows file commands
such as new, open, save, etc. This menu also has functions for compiling
CLC programs, archiving user programs and variables and printing CLC
programs. For the purpose of this manual, only Program Management will be
covered in this section. For a complete description of all the File menu
selections, refer to the VisualMotion Reference manual.

Figure 2-2: VisualMotion File Menu screen

DOK-VISMOT-VM*-06VRS**-WA02-AE-P • 03/99



Indramat Bosch.rar > Karty montażowa.pdf

engineering

mannesmann
Rexroth

DIAX02
Plug-In Modules for Digital Intelligent Drive
Controllers
Project Planning Manual
DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

276492

Indramat

Plug-in module for digital intelligent drive controllers

Title

DIAX02
Plug-in module for digital intelligent drive controllers

Type of documentation
Document code
Internal file reference

Project Planning Manual
DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P
• Mappe 11a / Register R
• 209-0076-4305-01

The purpose of this
documentaiton

This document supports electronic construction at the machine
manufacturer.
The technical data, terminal diagrams and signal paths for the individual
plug-in modules have been compiled here for that purpose.

Editing sequence

Status

Comments

209-0069-4356-00

Oct. 93

1st edition

209-0069-4356-01

May 95

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Copyright

Document designation of previous
editions

March 97

new edition

© INDRAMAT GmbH, 1993
Copying this document and giving it to others and the use or
communication of the contents hereof without express authority, are
forbidden. Offenders are liable for the payment of damages. All rights
reserved in the event of the grant of a patent or the registration of a utility
model or design. (DIN 34-1)

Validity

Published by

All rights are reserved with respect to the content of this documentation
and the availability of the product.
INDRAMAT GmbH • Bgm.-Dr.-Nebel-Str. 2 • D-97816 Lohr a. Main
Telefon 09352/40-0 • Tx 689421 • Fax 09352/40-4885
Abt. ENA (JH)

DOK-DIAX02-PLUG*IN*MOD-PRJ1-DE-P

Plug-in module for digital intelligent drive controllers

Contents
1 About This Document

1-1

1.1 Areas of Use of the Plug-In Modules................................................................................................... 1-1

2 Storage and Transport Conditions of the Plug-In Modules

2-1

2.1 Storage and Transport Conditions of the Plug-In Modules.................................................................. 2-1

3 Mechanical Design of the Plug-In Modules

3-1

3.1 Plug-In Modules with Plastic and Metal Front Plates........................................................................... 3-1
3.2 Type Codes ......................................................................................................................................... 3-2

4 Ground Reference of the Plug-In Module Connections

4-1

4.1 Low-voltage loops DC 5...24 V and galvanically coupled signal inputs and outputs ........................... 4-1
4.2 Optocoupler Interface .......................................................................................................................... 4-1
4.3 Notes on Earth-Fault Monitoring.......................................................................................................... 4-2

5 Control Card CLC-D01.1A-FW

5-1

5.1 Terminal Diagram CLC-D01.1A-FW.................................................................................................... 5-1

6 Control card CLC-D02.1A-FW and CLC-D02.3A-FW

6-1

6.1 Terminal Diagram CLC-D02.1A-FW and CLC-D02.3A-FW ................................................................ 6-1

7 ANALOG interface with Absolute Encoder Emulator DAA01.1

7-1

7.1 General Information............................................................................................................................. 7-1
7.2 Terminal Diagram DAA01.1................................................................................................................. 7-2
7.3 Technical Data..................................................................................................................................... 7-3

8 ANALOG interface with Incremental encoder emulator DAE01.1

8-1

8.1 General Information............................................................................................................................. 8-1
8.2 Terminal Diagram DAE01.1................................................................................................................. 8-2
8.3 Technical Data..................................................................................................................................... 8-3

9 ARCNET Coupler Card DAK01.1A

9-1

9.1 Connecting an ARCNET Coupler Card DAK01.1A.............................................................................. 9-1

10 INTERBUS-S interface module DBS02.1-FW

10-1

10.1 General Information......................................................................................................................... 10-1
10.2 Terminal Diagram ............................................................................................................................ 10-2
10.3 Technical Data................................................................................................................................. 10-3
INTERBUS-S .............................................................................................................................. 10-3

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Contents

I

Plug-in module for digital intelligent drive controllers

External Inputs ............................................................................................................................ 10-3

11 INTERBUS-S - interface module DBS02.2-FW

11-1

11.1 General Information......................................................................................................................... 11-1
11.2 Terminal Diagram ............................................................................................................................ 11-2
11.3 Technical Data................................................................................................................................. 11-3
INTERBUS-S .............................................................................................................................. 11-3
External inputs ............................................................................................................................ 11-3

12 INTERBUS-S Slave Module DBS03.1-FW

12-1

12.1 General Information......................................................................................................................... 12-1
12.2 Terminal Diagram ............................................................................................................................ 12-1
12.3 Technical Data................................................................................................................................. 12-2
INTERBUS-S .............................................................................................................................. 12-2
External inputs ............................................................................................................................ 12-2

13 Input / output interface DEA04.1, DEA05.1, DEA06.1

13-1

13.1 General Information......................................................................................................................... 13-1
13.2 Terminal Diagram ............................................................................................................................ 13-2
13.3 Technical Data - DEA04.1, DEA05.1, DEA06.1 .............................................................................. 13-3

14 Input / output interface DEA04.2, DEA05.2, DEA06.2

14-1

14.1 General Information......................................................................................................................... 14-1
14.2 Terminal Diagram ............................................................................................................................ 14-2
14.3 Technical Data - DEA04.2, DEA05.2, DEA06.2 .............................................................................. 14-3

15 Input / output interface DEA28.1, DEA29.1, DEA30.1

15-1

15.1 General Information......................................................................................................................... 15-1
15.2 Terminal Diagram ............................................................................................................................ 15-2
15.3 Technical data - DEA28.1, DEA29.1, DEA30.1 ............................................................................... 15-3

16 Position Interface for Square-Wave Signals DEF01.1 and DEF02.1

16-1

16.1 General Information......................................................................................................................... 16-1
16.2 DEF01.1 and DEF02.1 Connector Assignments ............................................................................. 16-1
16.3 Technical data - DEF01.1 and DEF02.1.......................................................................................... 16-2

17 Encoder Interface DFF01.1

17-1

17.1 General Information......................................................................................................................... 17-1
17.2 Terminal Diagram ............................................................................................................................ 17-2

18 Positioning Module DLC01.1

18-1

18.1 General Information......................................................................................................................... 18-1
18.2 Terminal Diagram ............................................................................................................................ 18-1

19 Positioning Module DLC02.1-FW

19-1

19.1 General Information......................................................................................................................... 19-1
19.2 Terminal Diagram ............................................................................................................................ 19-2

II Contents

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

20 High-Resolution Position Interface for Sine Signals DLF01.1

20-1

20.1 General Information......................................................................................................................... 20-1
20.2 Terminal diagrams........................................................................................................................... 20-2
20.3 Technical data - DLF01.1 ................................................................................................................ 20-4

21 Profibus Interface DPF02.1/03.1/04.1

21-1

21.1 General Information......................................................................................................................... 21-1
21.2 Terminal Diagram ............................................................................................................................ 21-2
21.3 Technical Data................................................................................................................................. 21-3

22 Profibus Interface DPF05.1-FW

22-1

22.1 General Information......................................................................................................................... 22-1
22.2 Terminal Diagram ............................................................................................................................ 22-1
22.3 Technical Data................................................................................................................................. 22-2

23 Analog Signal Interface DRF01.1

23-1

23.1 General Information......................................................................................................................... 23-1
23.2 Terminal Diagram DRF01.1............................................................................................................. 23-1
23.3 Technical data - DRF01.1................................................................................................................ 23-2

24 Summer Input Interface DSE01.1

24-1

24.1 General Information......................................................................................................................... 24-1
24.2 Terminal Diagram ............................................................................................................................ 24-3
24.3 Technical data - DSE01.1................................................................................................................ 24-4
24.4 Start-Ups.......................................................................................................................................... 24-6

25 SERCOS interface DSS01.1

25-1

25.1 General Information......................................................................................................................... 25-1
25.2 Terminal Diagram ............................................................................................................................ 25-1
25.3 Technical data - DSS01.1................................................................................................................ 25-2

26 SERCOS interface DSS01.3

26-1

26.1 General Information......................................................................................................................... 26-1
26.2 Terminal Diagram ............................................................................................................................ 26-1
26.3 Technical data - DSS01.3................................................................................................................ 26-2

27 Gear Encoder Interface DZF01.1

27-1

27.1 General Information......................................................................................................................... 27-1
27.2 Terminal Diagram ............................................................................................................................ 27-1
27.3 Power supply of the external measuring system ............................................................................. 27-2

28 Gear Encoder Interface DZF02.1

28-1

28.1 General Information......................................................................................................................... 28-1
28.2 Terminal Diagram ............................................................................................................................ 28-1
28.3 Power supply of the external measuring system ............................................................................. 28-2

29 Plug-In Module Accessories

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

29-1

Contents

III

Plug-in module for digital intelligent drive controllers

29.1 Encoder Branching DGA01.2 for encoders with sinusoidal 1VSS voltage signals .......................... 29-1
General Information .................................................................................................................... 29-1
Terminal Diagram ....................................................................................................................... 29-2
Dimensional sheet - DGA01.2 ................................................................................................... 29-3
Technical Data ............................................................................................................................ 29-3
29.2 Line Driver DGV01.1 for Measuring Systems with Current Signals................................................. 29-6
Terminal Diagram - Line driver DGV01.1 ................................................................................... 29-6
Dimensional sheet - Line driver DGV01.1 .................................................................................. 29-6

30 Index

30-1

IV Contents

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

1

About This Document

1.1

Areas of Use of the Plug-In Modules
The plug-in modules documented here are intended for use in digital drive
controllers belonging to the DIAX02 drive family.
Depending on the selected configured drive controller, various plug-in
modules can be inserted into the slots of the drive controller.
Which plug-in module can be combined with which software is outlined in
the document " Drive Configurations " .

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

About This Document 1-1

Plug-in module for digital intelligent drive controllers

Notes:

1-2 About This Document

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

2

Storage and Transport Conditions of the Plug-In
Modules

2.1

Storage and Transport Conditions of the Plug-In Modules

Protection against electrostatic
loads

Electrostatic loads endanger electronic components. Objects that come
into contact with components and printed circuit boards must be
discharged by grounding. For example,
• the human body by touching a conductive, grounded object
• the soldering iron when soldering
• parts and tools must be placed on a conductive surface
Note:

Temperature and Humidity

Such endangered parts as, e.g., the plug-in modules may only
be stored and shipped in conductive packaging.

Ambient temperature during operation

+5...+45°C

Ambient temperature during storage and
transport

-30...+85°C

Allowable relative humidity

max. 95%

Allowable absolute humidity

max. 25g water/m³

Fig. 2-1: Allowable Temperature and Humidity

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Storage and Transport Conditions of the Plug-In Modules 2-1

Plug-in module for digital intelligent drive controllers

Notes:

2-2 Storage and Transport Conditions of the Plug-In Modules

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

3

Mechanical Design of the Plug-In Modules

3.1

Plug-In Modules with Plastic and Metal front plates
The plug-in modules for drive controllers belonging to the DIAX03 and
DIAX04 drive families have a metal front plate with two knurled screws
(top and bottom) (see Fig. 3-1).
The plug-in modules for drive controllers belonging to the DIAX03 and
DIAX04 drive families (see Fig. 3-1) can therefore not be inserted into
drive controllers of the DIAX03 drive family as the plug-in module cannot
be mounted into the drive controller.

Plug-in module for drive
controllers belonging to
the DIAX03 and DIAX04
drive families

Plug-in module for drive
controllers belonging to
the DIAX02 drive family
Plastic front panel

Snap device

Metal front panel

Screw

Metal front panel

Knurled screw
H01X2X1P.fh5

Fig. 3-1: Plug-in module with plastic and metal front plates

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Mechanical Design of the Plug-In Modules 3-1

Plug-in module for digital intelligent drive controllers

3.2

Type Codes
The plug-in module type code has been placed at the top of the front
plate. The type designation can cover two lines. The designation -FW is
not on the front plate of the plug-in module. This designation specifies that
the plug-in module is equipped with firmware.

Plug-in modules for drive controllers
of the DIAX02 drive family
Type codes:
Product name

Example:

DSS 01.3 A - FW

DSS

Series

01

Version

3

Plug-in modules without
designation or designated
with an " A " for the DIAX02 line

A

Firmware
designation signifiying that
firmware must be ordered
as separated item

FW

Plug-in modules for drive controllers
of the DIAX03 and DIAX04 drive family
Type codes:
Product name

Exampl DSS 02.1 M - FW
DDS

Series

02

Version

1

Plug-in modules for
DIAX03 and DIAX04 lines

M

Firmware
designation signifiying that
firmware must be ordered
as separated item

FW

T01X2X1P.fh5

Fig. 3-2: Type code

3-2 Mechanical Design of the Plug-In Modules

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

4

Ground Reference of the Plug-In Module
Connections

4.1

Low-voltage loops DC 5...24 V and galvanically coupled
signal inputs and outputs
All connections and terminals with voltages of between 5 and 50 volts in
INDRAMAT products are protective extra-low voltages (PELV = Protective
Extra Low Voltage).
They are contact protected in terms of the following standards:
• international: IEC 364-4-411.1.5
• European countries within the EU: EN 50178/1994, section 5.2.8.1.
These connections are grounded electric circuits. The reference potential
of these circuits designated 0VM, GND or 0VL at the supply unit is
connected with the housing and thus grounded. The signal connections
and terminals of the drive controllers are a part of these circuits.
A separation of the ground connection is -- even for test purposes -- not
possible for reasons of safety. If these circuits are isolated from the
housing (ground potential), then a proper functioning of the electronic
components could no longer be guaranteed.
Which connections this applies to is specified in the terminal diagram of
the electrical equipment.

4.2

Optocoupler Interface
The extra-low voltage loops (e.g., DC 24 V) for operating the plug-in
modules must be grounded, i.e., the OV potential must be connected to
the central earth point in the control cabinet. Even if the DC 24 V electric
circuits of the plug-in modules are generally galvanically isolated, this
grounding still remains necessary (see Fig. 4-1).
Every day use has shown that a non-grounded voltage loop can transmit
interference signals, under some circumstances, via the coupler capacity
of the optocoupler. This, in turn, can generate error messages in the
drive.
The galvanic isolation of the plug-in modules which implements the
optocoupler prevents AC/DC currents from being conducted over the
evaluation electronics.

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Ground Reference of the Plug-In Module Connections 4-1

Plug-in module for digital intelligent drive controllers

External mains section in the
control cabinet

Drive controller

Voltage supply DC+24V

+UL

DC +24V

0VL

0V

Central
grounding
point
A24X2X1P.fh5

Fig. 4-1:

4.3

Connecting the DC 24 V voltage source for the optocoupler interface

Notes on Earth-Fault Monitoring
Due to the ground connections of the above-referenced electric circuits,
earth-fault monitoring of INDRAMAT drive and control systems is
basically not possible. The grounding of the electric circuit is needed to
secure sufficient operating safety and reliability.
An earth-fault monitor only makes sense with relay switches to detect the
ground faults which frequently occur there. Electronic equipment does not
need earth-fault monitoring and generally does not achieve its intended
purpose, namely, increased operating safety.

4-2 Ground Reference of the Plug-In Module Connections

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

5

Control Card CLC-D01.1A-FW

5.1

Terminal Diagram CLC-D01.1A-FW
CLC-D01.1

2 pin plug-in screw clamps
stock no.: 253 897
X29
1

1

BbN

" ready " contact

BbN

2

2
BbN
X 29
BbN

FSMA -conn. 2.2 ø INS 0418
6.0 ø INS 0426
X25

LWL interface
transmitter

X25

TX

TX

X26

X26

LWL interface
receiver

RX

9 pin D-SUB conn.
INS 0456
stock no.: 257 046

X27

6

TXA

3

RXA

1

1

TXA4xx

4

4

TXA4xx

5

5

RXA4xx

6

6

RXA4xx

7

7

8

8

9

9

9 pin D-sub. conn.
INS 0456
stock no.: 257 046

GND

9

1

5

X 28

2

3

6

1

ZT

1

+5 V

100R

View onto
front panel

X28
2

2

TXB

3

3

RXB

1

1

TXB4xx

4

4

TXB4xx

5

5

RXB4xx

6

GND
+5 V
input for
reset key

5

X 27

9

2

input for
reset key

RX

6

RXB4xx

7

7

8

8

9

9

GND
100R

+5 V
A01X2X1P.fh5

Fig. 5-1: Terminal Diagram CLC-D01.1A-FW

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Control Card CLC-D01.1A-FW

5-1

Plug-in module for digital intelligent drive controllers

X27/X28
TXA/B

2

RXA/B

3

GND

7

CLC - D02

R01X2X1P.fh5

Fig. 5-2: Terminal Diagram RS 232

X27/X28
1

TXA/B4xx

4

TXA/B4xx

5

RXA/B4xx

CLC - D02

6

RXA/B4xx

7

GND

R02X2X1P.fh5

Fig. 5-3: Terminal Diagram RS 422

X27/X28
1

TXA/B4xx

4

TXA/B4xx

5

CLC - D02

6
7

GND

R03X2X1P.fh5

Fig. 5-4: Terminal Diagram RS 485

Parameter

RS 232

RS 422

RS 485

Type

non-symmetric

symmetric

symmetric

Maximum cable length

15m

1200m

1200m

Max. transmission rate

38400 baud

9600 baud

9600 baud

Max. transmitter output
voltage

±15 V

±5 V*

±5 V*

Max. receiver input
voltage

±25 V

±14 V*

-14 V*

Input sensitivity

±3 V

±200 mV

±200 mV

Input resistance

3...7 kΩ

4 kΩ

12 kΩ

*) Differential signals
Fig. 5-5: Technical data - RS 232, RS 422, RS 485
BbN contact, X29

Name

Unit

max.

Switching voltage

V

125

Switching current

A

8

Switching power

W

50...220 W
(voltage dependent)

Fig. 5-6: Technical data - BbN contact, X29

5-2 Control Card CLC-D01.1A-FW

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

Technical data - fiber optic
cable interface
Name

Unit

Wert

max. transmission power with
opt. low-level

PSmaxL

dBm/µW

-28.2/1.5

min. transmission power with
opt. high-level

PSminH

dBm/µW

-7.5/180

max. transmission power with
opt. high-level

PSmaxH

dBm/µW

-3.5/450

λp
λp

nm
nm

640…675 nm (0° C..55° C)
- 30 nm (25° C)

max. input power with opt. lowlevel

PEmaxL

dBm/µW

-31.2/0.75

min. input power with opt. highlevel

PEminH

dBm/µW

-20/10

max. input power with opt.
high-level

Transmitter
data Tx

Abbreviation

PEmaxH

dBm/µW

-5/320

PSminH…PEminH

dB

12.5

wavelength of transmitter
diode: peak wavelength
spectral bandwidth
Receiver data
Rx

max. attentuation of
transmission path

The transmission power can be set via the relevant software parameter.
Fig. 5-7: Technical data - fiber optic cable interface
Battery

There is a 3 voltage button cell on the CLC for RAM back up.
Note:

Once the battery is dead, both C and A parameters could be
lost. Therefore, back up the parameters!

INDRAMAT stock number: 254 284
Lifespan of battery

The battery has a capacity of at least 75% at the time of delivery.
Reaching about 10% of total capacity means the battery is empty.
The lifespan of the battery depends on how the CLC is operated. The
following table offers an approximation:
Ambient
temperature

3 shift
operation

2 shift
operation

1 shift
operation

Storage

25° C
35° C
45° C

4 years
4 years
3 years

4 years
3 years
2 years

4 years
2 years
1.2 years

3 years
1.5 years
0.8 years

Fig. 5-8: Battery service lifespan

Notes:

Replacing the battery

The battery is empty at the end of this time and must always
be replaced.

Upon removal of the battery, all parameters remain backed up for at least
one minute.
Procedure:






DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

have replacement batteries handy
switch machine off
pull CLC card
pull old battery out
insert new battery no more than one minute later

Control Card CLC-D01.1A-FW

5-3

Plug-in module for digital intelligent drive controllers

Notes:

5-4 Control Card CLC-D01.1A-FW

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

Control card CLC-D02.1A-FW and CLC-D02.3A-FW

6.1

Terminal Diagram CLC-D02.1A-FW and CLC-D02.3A-FW

A

CLC-D02.1

6

H4

FSMA conn. 2.2 ø INS0418
6.0 ø INS0426
X25

LWL interface
transmitter

X25

TX

TX

X26

LWL interface
receiver

X27
TXA

3

3

RXA

1

1

TXA4xx

4

4

TXA4xx

5

5

RXA4xx

6

6

RXA4xx

7

7

8

input for
reset key

2

8

9

9

GND
100R

ZT

9 pin D-sub conn.
INS0456
stock no.: 257 046

+5 V

1
View onto
front panel

X28
2

2

TXB

3

3

RXB

1

1

TXB4xx

4

4

TXB4xx

5

5

RXB4xx

6

GND
+5 V
input for
reset key

X 28

2

RX

X 27

9 pin D-sub conn.
INS0456
stock no.: 257 046

X26

RX

6

RXB4xx

7

7

8

8

9

9

GND
100R

+5 V
A02X2X1P.fh5

Fig. 6-1: Terminal Diagram CLC-D02.1A-FW and CLC-D02.3A-FW

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Control card CLC-D02.1A-FW and CLC-D02.3A-FW

6-1

Plug-in module for digital intelligent drive controllers

X27/X28
TXA/B

2

RXA/B

3

GND

7

CLC - D02

R01X2X1P.fh5

Fig. 6-2: Terminal Diagram RS 232

X27/X28
1

TXA/B4xx

4

TXA/B4xx

5

RXA/B4xx

CLC - D02

6

RXA/B4xx

7

GND

R02X2X1P.fh5

Fig. 6-3: Terminal Diagram RS 422

X27/X28
1

TXA/B4xx

4

TXA/B4xx

5

CLC - D02

6
7

GND

R03X2X1P.fh5

Fig. 6-4: Terminal Diagram RS 485

Parameter

RS 232

RS 422

RS 485

Type

non-symmetric

symmetric

symmetric

Maximum cable length

15m

1200m

1200m

Max. transmission rate

38400 baud

9600 baud

9600 baud

Max. transmitter output
voltage

±15 V

±5 V*

±5 V*

Max. receiver input
voltage

±25 V

±14 V*

-14 V*

Input sensitivity

±3 V

±200 mV

±200 mV

Input resistance

3...7 kΩ

4 kΩ

12 kΩ

*) Differential signals
Fig. 6-5: Technical data - RS 232, RS 422, RS 485

6-2 Control card CLC-D02.1A-FW and CLC-D02.3A-FW

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

Technical data - fiber optic
cable interface
Name

Unit

Wert

max. transmission power with
opt. low-level

PSmaxL

dBm/µW

-28,2/1,5

min. transmission power with
opt. high-level

PSminH

dBm/µW

-7.5/180

max. transmission power with
opt. high-level

PSmaxH

dBm/µW

-3.5/450

λp
λp

nm
nm

640…675 nm (0° to 55° C)
- 30 nm (25° C)

max. input power for opt. low
level

PEmaxL

dBm/µW

-31.2/0.75

min. input power for opt. high
level

PEminH

dBm/µW

-20/10

max. input power for opt. high
level

Transmitter
data Tx

Abbreviation

PEmaxH

dBm/µW

-5/320

PSminH…PEminH

dB

12.5

wavelength of transmitter
diode: peak wavelength
spectral bandwidth
Receiverdata Rx

max. attenuation of the
transmission path

Transmission output can be set with software parameters..
Fig. 6-6: Technical data - fiber optic cable interface
Battery

There is a 3 volt button cell for RAM back-up.
Note:

Once the battery is dead, both C and A parameters could be
lost. Therefore, back up the parameters!

INDRAMAT stock number: 254 284
Battery lifespan

The battery has a capacity of at least 75% at the time of delivery.
Reaching about 10% of total capacity means the battery is empty.
The lifespan of the battery depends on how the CLC is operated. The
following table offers an approximation:
Ambient
temperature

3 shift
operations

2 shift
operations

1 shift
operations

Storage

25° C
35° C
45° C

4 years
4 years
3 years

4 years
3 years
2 years

4 years
2 years
1,2 years

3 years
1,5 years
0,8 years

Fig. 6-7: Battery lifespan

Notes:

Battery tauschen

At the end of this time, the battery is empty and must be
replaced.

Upon removal of the battery, all parameters remain backed up for at least
one minute.
Procedure:






DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

have replacement batteries handy
switch machine off
pull CLC card
pull old battery out
insert new battery no more than one minute later

Control card CLC-D02.1A-FW and CLC-D02.3A-FW

6-3

Plug-in module for digital intelligent drive controllers

Notes:

6-4 Control card CLC-D02.1A-FW and CLC-D02.3A-FW

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

7

ANALOG interface with Absolute Encoder
Emulator DAA01.1

7.1

General Information
Plug-in module DAA01.1 makes it possible to operate the digital intelligent
AC servo drive with conventional NC control units via an analog interface.
It also contains control inputs and signal outputs for communication with a
connected control unit and outputs absolute position feedback values as
per SSI standards (synchronous serial interface).

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

ANALOG interface with Absolute Encoder Emulator DAA01.1 7-1

Plug-in module for digital intelligent drive controllers

Terminal Diagram DAA01.1
X15

GND analog
1

±10V analog input
temperature prewarning
control enable
drive halt
current reduction 1

1

E1

2

2

E2

3

3

TVW

4

4

RF

5

5

AH

6

6

Ired1

DC +24V external
DC 0V external

OFFSETKOM.

1

X15
E1

7

7

Ired2

8

8

+UL

9

9

0VL

10

current reduction 2

DAA01.1

7.2

10

E2
TVW
RF
AH
Ired1
Ired2
+UL

10-pin plug-in screw clamp
MC 1.5 / 10 ST; stock no.: 241 647

0VL

10
X16

absoluteencoder emulator (SSI data format)
15-pin D-SUB conn.
INS 0519 (screw mounting)
stock no.: 263 365

X16

3

4

4

5

5

DATA (+)

6

6

DATA (-)

7
2

9

DC 0V ext.
BN 12
WH 12 DC +24V ext.

3

2

DATA (-)

1

7

GN

8

1

cable (2x1.0 + 4x2x0.25)C
type: INK 0209
1)
DATA (+)
BN

8

9

10

10

11

11

0V
+U

12

12

BK

pulse (+)

13

13

pulse (+)

RD

pulse (-)

14

14

pulse (-)

15

View onto
front panel

15
A03X2X1P.fh5

1) Color coding applies to INDRAMAT cable INK 0209

Fig. 7-1: Terminal Diagram - DAA01.1

7-2 ANALOG interface with Absolute Encoder Emulator DAA01.1

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

7.3

Technical Data
Analog interface

Designation

Unit

Input voltage 1)

min.

max.

E1

-10

+10

V

-10

+10

|E1-E2|

V

E1

mA

-0.25

+0.25

E2

Input current

V

E2

mA

-0.5

+0.5

10

16

1) The input voltage resolution equals: 20V/2 =0.3 mV
Fig. 7-2: Analog command value interface data
Power supply /
inputs and outputs

Designation

Unit

External power supply+UL

V

min.

type

max.

18

24

32

Current consumption- +UL

mA

Inputs

UHigh

V

14

24

100
32

RF, AH, Ired1, Ired2

ULow

V

0

& lt; 1

3

Output TVW

IOut

mA

100

Fig. 7-3: Data - power supply and digitial inputs and outputs
Differential input analog
command value

X15
20K/0.1%

20K/0.1%

1

E1

+
E2 2
20K/0.1%

20K/0.1%

0VM

I01X2X1P.fh5

Fig. 7-4: Input circuit for analog interface
Schematic diagram input/output circuit

X15
+UL

DC

8

+12 V
DC
1/4 HEF40244

input
(RF, AH, Ired) 5K
0 VTTL
0 VL

12V

9

10nF

5K

+UL
5R2

output
(TVW)

ϑ

3

9R4 (PTC)

Tv

0 VL

I02X2X1P.fh5

Fig. 7-5: Schematic diagram - input/output circuit

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

ANALOG interface with Absolute Encoder Emulator DAA01.1 7-3

Plug-in module for digital intelligent drive controllers

Designation

Unit

Power supply +Uext

V

Current consumption- +Uext

min.

mA

max.

24

32

100

10

type

200

Transmitter
Output current
Low level

IOL

mA

60

High level

IOH

mA

-60

Output voltage IVD01I with I0=0

V

0

5.25

IVD01I if I0=0

V

1.5

5.25

IVD02I if RL=54Ω

V

1.5

5.0

0.2

Differential output voltage

Receiver
Differential input voltage
Low level

VTL

V

High level

VTL

V

Hysteresis

VHVS

mV

Fig. 7-6:

0.2
50

Power supply and signal level of absolute encoder emulator

Absolute encoder - output
circuit

X16
DC

11

+Uext

+5 V
DC

pulse (+)

13
100 R

input
circuit

0 Vext

2.2 nF

SN 75179 B

2.2 nF

100 R

pulse (-)

14

0 Vext
+5 V

data (+)

5

output
circuit
data (-)

0 Vext

SN 75179 B

6

10

0Vext.

Detailled data see data sheets SN 75179 B (Texas Instruments)
I03X2X1P.fh5

Fig.

7-7:

7-4 ANALOG interface with Absolute Encoder Emulator DAA01.1

Absolute

encoder

-

output

circuit

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

Standard cable for X16

DAA01.1

conn. INS 0519
Ferrules for intermediate
clamping

INK 0209

45
70
IKS 0031

Y01X2X1P.fh5

Fig. 7-8: Standard cable for X16
Recommended data
transmission pulse frequency

The pulse frequency depends on the cable length.
Cable length in m

Pulse frequency in kHz

& lt; 50

& lt; 400

& lt; 100

& lt; 300

& lt; 200

& lt; 200

& lt; 400
Fig. 7-9: Cable length and pulse frequency

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

& lt; 100

ANALOG interface with Absolute Encoder Emulator DAA01.1 7-5

Plug-in module for digital intelligent drive controllers

Sampling code:

gray code

Extent of data:

4096 revolutions

Resolution:

4096 increment / revolution

Data format:

Actual feedback output in
absolute format

24 Bit + PFB

Counting direction:

switchable

Data transmission:

synchronous, serial

Input, output circuit:

Driver per EIA RS 422 A

Least-significant bit:

G0

Most-significant bit:

G23

Pulse frequency :

fT= 100 kHz ... 1 MHz

Pulse signal period

T = 1 µs ... 10 µs

Monoflop time:

tm= 15 µs ... 25 µs

Pulse break:

Tp = 40 µs

Delay time (max.):

tv = first pulse 540 ns, additional 360 ns

Power Failure Bit (PFB):

not used and is always logically " 0 "

Tp & gt; tm-T/2

T

pulse +
1

data

2

3

4

5

6

7

8

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

1 1 G23 G22 G21 G20 G19 G18 G17 G16 G15 G14 G13 G12 G11 G10 G9 G8 G7 G6 G5 G4 G3 G2 G1 G0 PFB

resolution for 4096 revolutions

tm-T/2

0

1
1

2

1 G23 G22

resolution for 1 revolution

T

pulse

Tp
tm

tv

serial data
G23

G22

monoflop P / S

G0

PFB

m
S01X2X1P.fh5

Fig. 7-10: Schematic diagram - signal paths

DANGER

Error in control of motors and moving parts
Bodily injury and property damage caused by unwanted
axis motions.
If breaks in the power supply +Uext occur with less than
10 V over a period greater than 100 µs, then encoder
information could be incorrect.
⇒ Activate lag distance monitor in control unit!

7-6 ANALOG interface with Absolute Encoder Emulator DAA01.1

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

Sampling code:

gray code

Extent of data:

1 table rotation

Resolution:

262 144 increments per table rotation

Data format:

Actual position feedback output
in modulo format

18 Bit

Counting direction:

switchable

Data transmission:

synchronous, serial

Input, output circuit:

Driver per EIA RS 422 A

Least-significant bit:

G0

Most-significant bit:

G17

Pulse frequency :

fT= 100 kHz ... 1 MHz

Pulse signal period

T = 1 µs ... 10 µs

Monoflop time:

tm= 15 µs ... 25 µs

Pulse break:

Tp = 40 µs

Delay time (max.):

tv = first pulse 540 ns, additional 360 ns

Stored parallel information:

m

Tp & gt; tm-T/2

T

pulse +
1

data

2

3

4

5

6

7

8

9 10 11 12 13 14 15 16 17 18

1 1 G17 G16 G15 G14 G13 G12 G11 G10 G9 G8 G7 G6 G5 G4 G3 G2 G1 G0

tm-T/2

0

1
1

2

1 G17 G16

T

pulse

Tp
tm

tv

serial data
G17
monoflop P / S

G16

G1

G0

m
S02X2X1P.fh5

Fig. 7-11: Schematic diagram - signal paths

DANGER

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Error in control of motors and moving parts
Bodily injury and property damage caused by unwanted
axis motions.
If breaks in the power supply +Uext occur with less than
10 V over a period greater than 100 µs, then encoder
information could be incorrect.
⇒ Activate lag distance monitor in control unit!

ANALOG interface with Absolute Encoder Emulator DAA01.1 7-7

Plug-in module for digital intelligent drive controllers

Notes:

7-8 ANALOG interface with Absolute Encoder Emulator DAA01.1

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

8

ANALOG interface with Incremental encoder
emulator DAE01.1

8.1

General Information
The plug-in module DAE01.1 makes it possible to operate the digital
intelligent AC servo drive with conventional NC control units via analog
interfaces. It also contains control inputs and signal outputs for
communication with a connected NC control unit and generates
incremental encoder signals which can be used as position feedback
values.

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

ANALOG interface with Incremental encoder emulator DAE01.1 8-1

Plug-in module for digital intelligent drive controllers

Terminal Diagram DAE01.1
X13

GND analog
1

±10V analog input
temperature prewarning
control enable
drive halt
current reduction 1

1

E1

2

2

E2

3

3

TVW

4

4

RF

5

5

AH

6

6

Ired1

DC +24V external
DC 0V external

7

7

8

8
9

1

X13
E1

+UL

9

OFFSETKOM.

Ired2

0VL

10

current reduction 2

DAE01.1

8.2

10

E2
TVW
RF
AH
Ired1
Ired2
+UL

10-pin plug-in screw clamp
MC 1.5 / 10 ST; stock no.: 241 647

0VL

10
X14

incremental encoder emulator
cable (2x1.0 + 4x2x0.25)C
type: INK 0209
1)
Ua2
GY

X14
8

8

Ua2

PK

Ua2

1

1

Ua2

RD

Ua0

3

3

Ua0

BK

Ua0

4

4

Ua0

BN

Ua1

5

5

Ua1

GN

Ua1

6

6

Ua1

7

7

2

2

9

9

10

10

11

11

12

12

13

13

14

14

15

15

WH

BN

12

12

DC 0V extern
DC +5V extern

15-pin D-SUB conn.
INS 0519 (screw mounting)
stock no.: 263 365

0V

View onto
front panel

+5V

A04X2X1P.fh5

1)Color coding applies to INDRAMAT cable: INK 0209
Fig. 8-1: Terminal Diagram - DAE01.1

8-2 ANALOG interface with Incremental encoder emulator DAE01.1

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

8.3

Technical Data
Analog interface

Designation

Unit

Input voltage 1)

min.

max.

E1

-10

+10

V

-10

+10

|E1-E2|

V

E1

mA

-0,25

+0,25

E2

Input current

V

E2

mA

-0,5

+0,5

10

16

1) The input voltage resolution equals: 20V/2 =0.3 mV
Fig. 8-2: Analog command value interface data
Power supply /
inputs and outputs

Designation

Unit

External power supply+UL

min.

type

max.

V

18

24

32

Current consumption- +UL

mA

Inputs

UHigh

V

14

24

100
32

RF, AH, Ired1, Ired2

ULow

V

0

& lt; 1

3

OutputTVW

IOut

mA

100

Fig. 8-3: Data - power supply and digitial inputs and outputs
Differential input analog
command value

X13
E1

1

20K/0.1%

20K/0.1%

+
E2 2
20K/0.1%

20K/0.1%

0VM

I04X2X1P.fh5

Fig. 8-4: Input circuit to the analog interface
Schematic diagram - input and
output circuits

+5Vext
C1
0.01µF

Ua

twisted
cable pair
Output

1/2 DS7820

DS3487M

C2
100pF

Ua
0Vext
Power driver
output circuit

strobe

Basic input circuit
on receiver side
I05X2X1P.fh5

Fig. 8-5: Schematic diagram - input and output circuits

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

ANALOG interface with Incremental encoder emulator DAE01.1 8-3

Plug-in module for digital intelligent drive controllers

Fig. 8-6: Incremental encoder output signals
Schematic diagram - input and
output circuits

X15
+UL

DC

8

+12 V
DC
1/4 HEF40244

input
(RF, AH, Ired) 5K
0 VTTL
0 VL

12V

9

10nF

5K

+UL
5R2

output
(TVW)

ϑ

3

9R4 (PTC)

Tv

0 VL

I02X2X1P.fh5

Fig. 8-7: Schematic diagram - input and output circuits

Designation

Unit

min.

type

max.

Power supply +5V

V

4.75

5

5.25

1.8

3.3

5.25

0.22

0.5

Current consumption- +5V

mA

Signal level at 40 mA

Uhigh

V

Ua0, Ua1, Ua2

Ulow

175

V

Output current

mA

40

Output frequency

kHz

504

Rise and fall time

ns

100

Reference point delay t1

ns

0

Edge distance t2

ns

400

Fig. 8-8:

15

30

Power supply and signal level of the incremental encoder emulators

8-4 ANALOG interface with Incremental encoder emulator DAE01.1

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

9

ARCNET Coupler Card DAK01.1A

9.1

Connecting an ARCNET Coupler Card DAK01.1A
The " ARCNET Coupler Card " is a plug-in card for the CLC-D 2 control
card and creates an interface to an ARCNET bus system.
The node number can be selected with a switch on the front plate.
The green LED on the front plate displays that the ARCNET interface has
been initialized and connected to the ARCNET bus.

H5

green LED for
ARCNET-SS
1 2 3 4 5 6 7 8

DIP switch for
selecting node
number
0 ... 255

A

DAK 01.1

Front plate DAK01.1A

switch position " ON "
switch position " OFF "
S5

Address set here:
11111101 = 253Dec corresponds to
FDHex
X 44

COAXIAL bushing for
ARCNET bus system

View onto
front panel

F01X2X1P.fh5

Fig. 9-1: Front plate DAK01.1A

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

ARCNET Coupler Card DAK01.1A

9-1

Plug-in module for digital intelligent drive controllers

Schematic diagram of an
ARCNET bus system

Matching
resistor
93 Ω

BNC
T adapter

Subscriber
1

Subscriber
2

Subscriber
3

Subscriber
4

.......

Active HUB

Subscriber
8
B01X2X1P.fh5

Fig. 9-2: Schematic diagram of an ARCNET bus system
Transmission media, bus
connection and bus termination

The network must be constructed with a coaxial cable type RG-62 or RG71 with an impedance of 93 Ω.
The final ARCNET bus subscriber must be terminated with a resistance of
93 Ω.
Each network subscriber must be connnected into the bus segment via a
T-BNC adapter.

Node number (subscriber
number)

The node number is needed to clearly identify a bus subscriber. This
node number must be set within a range of 0 to 255 once the network is
started up. Any change in the node number does not become effective
until the CLC-D has been switched off and then on once.

Bus connection - DAK

DAK 01.1A
L
High
impedance
transceiver
(HIT)

L

5k6

X44
4n7

BNC bushing

5k6

A05X2X1P.fh5

front panel / housing

Fig. 9-3: Bus conneciton - DAK

9-2 ARCNET Coupler Card DAK01.1A

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

10

INTERBUS-S interface module DBS02.1-FW

10.1 General Information
Operating modes

The module DBS02.1-FW makes a connection with digital drive
controllers of the DIAX02 drive family possible in the operating modes
• speed default as per DRIVECOM Profile 21
• referencing as per DRIVECOM Profile 22

Bus network subscriber

The module DBS02.1-FW is a bus network subscriber as defined by the
INTERBUS-S. Within one INTERBUS-S bus network installation it is
possible to combine this module with any other INTERBUS-S interface
module of any other manufacturer, if the module meets the specifications
as defined by the INTERBUS-S certificate. Up to 256 bus network
subscribers can be combined in one bus network.

Galvanic isolation

The bus network input and output of the INTERBUS-S interface module
DBS02.1-FW are galvanically isolated. This achieves the greatest
resistance to interference within the network.

LEDs for the INTERBUS-S

There are 8 diagnostic LEDs on the front to quickly check the functioning
of the DBS02.1 module. This diagnostics function of the INTERBUS-S
ring meets INTERBUS-S standards.

Note:

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

For further details on the functions, please see the relevant
Function Description documentation.

INTERBUS-S interface module DBS02.1-FW

10-1

Plug-in module for digital intelligent drive controllers

FW

DBS02.1

10.2 Terminal Diagram

External inputs X39
1

E1
E2
E3

H2

5

E4

3

Reference cam
Release of the brake
E-Stop

INTERBUS-S
diagnosis

H1

4

Event

OVL

2

X 39
0 VL
E1
E2
E3
E4

INTERBUS-S input X40
1

DO1

2

DI1
GND1

3

Incoming field bus

- RS 485
- D-SUB 9 pin
connector

free
free

4
5

7

DO1
DI1

8

free

9

free

6

X 40

- RS 485
- D-SUB 9 pin
bushing

INTERBUS-S output X41
1

DO2

2

DI2
GND2

3

5
6

DO2

7
8

DI2
free

9

Continuing field bus

RBST

X 41

free
+5V 2

4

View onto
front panel

A26X2X1P.fh5

Fig. 10-1: Terminal Diagram

Master circuit

DBS 02.X

X41
DO

DBS 02.X

X40

X40

1

1

DO1

1

1

DO1

1

1

2
DI
GND1 3

2

DI1
GND1

2

2

2

3

DI1
GND1

2

3

3

3

free
+5V

4

4

4

4

4

5

5

5

free
free

4

5

free
free

5

5

DO

6

6

6

6

6

7

7

7

7

DO1
DI1

6

DI
free

DO1
DI1

7

7

8

8

free

8

8

free

8

8

RBST 9

9

free

9

9

free

9

9

3

X41
DO2

X41
1

1

DO2

1

1

2
DI2
GND2 3

2

2
DI2
GND2 3

2

4
free
+5V 2 5

4

4

5

4
free
+5V 2 5

DO2

6

6

DO2

6

6

DI2
free

7

7

7

7

8

8

DI2
free

8

8

RBST 9

9

RBST 9

9

3

3

5

A27X2X1P.fh5

Fig. 10-2: Master interface connection with two bus network subscribers

10-2 INTERBUS-S interface module DBS02.1-FW

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

10.3 Technical Data
INTERBUS-S
Incoming interface
INTERBUS - S standard interface in accordance with DIN E 19258 for
bus network subscribers via a D-subminiature 9-pin connector. The
interface is completely galvanically isolated. There is a duplex interface
connection in it based on an RS 485 for coupling with the previous
participant in the INTERBUS - S ring.

Outgoing interface
INTERBUS - S standard interface in accordance with DIN E 19258 for
bus network subscribers via a D-subminiature 9-pin bushing. This
interface is also completely galvanically isolated. There is a duplex
interface connection in it based on an RS 485 for coupling with the
following participant. There is also a strobe signal to be able to detect a
continuing INTERBUS-S.

External Inputs
Module DBS02.1 has four hardware inputs (+24V).
X39

Designation

Input voltage for
high

Input voltage for
low

1

0VL

reference potential 0V

reference potential 0V

2

E1

+16 V... +32 V

-0.5 V ... +8 V

3

E2

+16 V... +32 V

-0.5 V ... +8 V

4

E3

+16 V... +32 V

-0.5 V ... +8 V

5
E4
+16 V... +32 V
Fig. 10-3: Signal assignment X39 external inputs

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

-0.5 V ... +8 V

INTERBUS-S interface module DBS02.1-FW

10-3

Plug-in module for digital intelligent drive controllers

Notes

10-4 INTERBUS-S interface module DBS02.1-FW

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

11

INTERBUS-S - interface module DBS02.2-FW

11.1 General Information
Plug-in module construction

The module DBS02.2-FW can only be operated together with positioning
module DLC02.1. The INTERBUS-S - interface module DBS02.2-FW is
inserted into the DLC02.1. Once screwed together with three bolts, the
DBS02.2 and DLC02.1 create one unit.
Module DBS02.2-FW together with the positioning module DLC02.1-FW
can be operated in different modes.

Operating modes

The mode determines the function in which the module operates.
The main mode for module DBS02.2 is positioning targeting in terms of
DRIVECOM - standard Profile 22. In addition to this mode, the module
also supports operation of the DLC02.1-FW with those functions
described in the documentation (DOK no. 109-0852-4102). The
conventional I/O level, in this case, is either completely or partially
replaced by the INTERBUS - S circuit.

Bus network subscriber

The module DBS02.2-FW represents a bus network subscriber in terms
of the INTERBUS-S definition. Within an INTERBUS-S bus network
installation it is possible to combine this module with any other
INTERBUS-S interface module from any other manufacturer, if the
module meets the requirements set forth in the INTERBUS-S certificate.
Up to 256 bus network subscribers can be interconnected in one bus
network installation.

Galvanic isolation

The INTERBUS-S interface module DBS02.2-FW has galvanically
isolated bus network inputs and outputs. This achieves the greatest
resistance to interference in the bus network.

LEDs for the INTERBUS-S

There are 8 diagnostic LEDs on the front to quickly check the functioning
of the DBS02.1 module. This diagnostics function of the INTERBUS-S
ring meets INTERBUS-S standards.
For further details on the functions, please see the Function Description
documentation.

Note:

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Please note, when disassembling or removing a plug-in
module from the drive controller that DBS02.2-FW is
connected with DLC02.1-FW.

INTERBUS-S - interface module DBS02.2-FW

11-1

Plug-in module for digital intelligent drive controllers

FW

DBS02.2

11.2 Terminal Diagram

External inputs X39
1

E1
E2
E3

H2

5

E4

3

Reference cam
Release of the brake
E-Stop

INTERBUS-S
diagnosis

H1

4

Event

OVL

2

X 39
0 VL
E1
E2
E3
E4

INTERBUS-S input X40
1

DO1

2

DI1
GND1

3

Incoming field bus

- RS 485
- D-SUB 9 pin
connector

frei
frei

4
5

7

DO1
DI1

8

frei

9

frei

6

X 40

- RS 485
- D-SUB 9 pin
bushing

INTERBUS-S output X41
1

DO2

2

DI2
GND2

3

5
6

DO2

7
8

DI2
frei

9

Continuing field bus

RBST

X 41

frei
+5V 2

4

View onto
front panel

A28X2X1P.fh5

Fig. 11-1: Terminal Diagram

Master circuit

DBS 02.X

X41
DO

DBS 02.X

X40

X40

1

1

DO1

1

1

DO1

1

1

2
DI
GND1 3

2

DI1
GND1

2

2

2

3

DI1
GND1

2

3

3

3

free
+5V

4

4

4

4

4

5

5

5

free
free

4

5

free
free

5

5

DO

6

6

6

6

6

7

7

7

7

DO1
DI1

6

DI
free

DO1
DI1

7

7

8

8

free

8

8

free

8

8

RBST 9

9

free

9

9

free

9

9

3

X41
DO2

X41
1

1

DO2

1

1

2
DI2
GND2 3

2

2
DI2
GND2 3

2

4
free
+5V 2 5

4

4

5

4
free
+5V 2 5

DO2

6

6

DO2

6

6

DI2
free

7

7

7

7

8

8

DI2
free

8

8

RBST 9

9

RBST 9

9

3

3

5

A27X2X1P.fh5

Fig. 11-2: Master interface connection with two bus network subscribers

11-2 INTERBUS-S - interface module DBS02.2-FW

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

11.3 Technical Data
INTERBUS-S
Incoming interface
INTERBUS - S standard interface in accordance with DIN E 19258 for
bus network subscribers via a D-subminiature 9-pin connector. The
interface is completely galvanically isolated. There is a duplex interface
connection in it based on an RS 485 for coupling with the previous
participant in the INTERBUS - S ring.

Outgoing interface
INTERBUS - S standard interface in accordance with DIN E 19258 for
bus network subscribers via a D-subminiature 9-pin bushing. This
interface is also completely galvanically isolated. There is a duplex
interface connection in it based on an RS 485 for coupling with the
following participant. There is also a strobe signal to be able to detect a
continuing INTERBUS-S.

External inputs
Module DBS02.2 has four hardware inputs (+24V) which can only be used
in conjunction with a DLC.

X39

Designation

Input voltage for
high

Input voltage for
low

1

0VL

reference potential 0V

reference potential 0V

2

E1

+16 V... +32 V

-0.5 V ... +8 V

3

E2

+16 V... +32 V

-0.5 V ... +8 V

4

E3

+16 V... +32 V

-0.5 V ... +8 V

5
E4
+16 V... +32 V
-0.5 V ... +8 V
Fig. 11-3: Signal assignment to X39 of the external inputs

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

INTERBUS-S - interface module DBS02.2-FW

11-3

Plug-in module for digital intelligent drive controllers

Notes

11-4 INTERBUS-S - interface module DBS02.2-FW

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

12

INTERBUS-S Slave Module DBS03.1-FW

12.1 General Information
The INTERBUS-S slave module DBS03.1-FW makes it possible to
integrate control module CLC-D into an INTERBUS-S system.
The INTERBUS-S interface of module DBS03.1-FW is constructed in
terms of a bus network interface and corresponds to the standards set
forth in the INTERBUS-S certificate.
Module DBS03.1-FW is designed as a plug-in module to be inserted
directly into the control module. Once screwed together with three bolts, it
creates one unit with the CLC-D.
Note:

Additional modules can be inserted into the DBS03.1-FW. This
is important when diassembling and removing!

stock no. 253897 X38

Terminal X38
has no function
with DBS03.1M

1
2

+24V
OVL

DBS03.1

12.2 Terminal Diagram

X 38
+24V
0 VL

stock no. 254006 X39
1

E1

2

E2
E3
OVL

3
4

X 39
E1
E2
E3
0 VL
H13

INS 0457 X40
1

DI1
GND1

3
4
5

free
free

7

DO1
DI1

8

free

9

free

6

X 40

Incoming bus

8 LEDs

DO1

2

H14

INS 0456 X41
1

DO2

2

DI2
GND2

3

5
6

DO2

7
8

DI2
free

9

Outgoing bus

RBST

X 41

free
+5V

4

View onto
front panel

A06X2X1P.fh5

Fig. 12-1: Terminal Diagram

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

INTERBUS-S Slave Module DBS03.1-FW

12-1

Plug-in module for digital intelligent drive controllers

12.3 Technical Data
INTERBUS-S
Incoming interface
INTERBUS - S standard interface in accordance with DIN E 19258 for
bus network subscribers via a D-subminiature 9-pin connector. The
interface is completely galvanically isolated. There is a duplex interface
connection in it based on an RS 485 for coupling with the previous
participant in the INTERBUS-S ring.

Outgoing interface
INTERBUS-S standard interface in accordance with DIN E 19258 for bus
network subscribers via a D-subminiature 9-pin bushing. This interface is
also completely galvanically isolated. There is a duplex interface
connection in it based on an RS 485 for coupling with the following
participant. There is also a strobe signal for the detection of a continuing
INTERBUS-S.

External inputs
Module DBS03.1-FW has three hardware inputs (+24V) which can only
be used in conjunction with a CLC-D if supported by the relevant
firmware. The signal states at these inputs are transmitted, regardless of
INTERBUS-S status (on/off) to the CLC-D but can also be queried by the
INTERBUS -S master via the PD or PCP channel.
X3

Designation

Input voltage for
high

Input voltage for
low

1

E1

+16 V... +32 V

-0.5 V ... +8 V

2

E2

+16 V... +32 V

-0.5 V ... +8 V

3

E3

+16 V... +32 V

-0.5 V ... +8 V

4

0VL

reference potential 0V

reference potential 0V

Fig. 12-2: Signal assignment X3 external inputs

Note:

12-2 INTERBUS-S Slave Module DBS03.1-FW

Module DBS03.1-FW has no INTERBUS-S repeater function
maintained by an external power supply if the DBS03.1-FW is
decoupled from the internal supply. Therefore, do not wire up
the X38 connector.

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

13

Input / output interface DEA04.1, DEA05.1, DEA06.1

13.1 General Information
These plug-in modules have 15 inputs and 16 outputs via which the drive
can exchange binary signals with a PLC.
The difference of the three types specified is the address.
To avoid confusion during installation, the D-subminiature plug-in
connectors are differently labelled.

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Input / output interface DEA04.1, DEA05.1, DEA06.1 13-1

Plug-in module for digital intelligent drive controllers

13.2 Terminal Diagram
Standard
cable IKS0123

X17/X32/X33

GYPK

IN 1

RDGN

3

IN 2

BKYE

4

IN 3

GNBU

5

IN 4

RDBU

6

IN 5

BNYE

7

IN 6

BNGY

8

IN 7

RDWH

9

IN 8

WHPK

10

IN 9

BKWH

11

IN 10

BNPK

12

IN 11

YEWH

13

IN 12

GNWH

14

IN 13

BUWH

15

IN 14

GNGY

16

OUT 0

GYWH

17

OUT 1

WH

18

OUT 2

VT

19

OUT 3

YE

20

OUT 4

PK

21

OUT 5

BU

22

OUT 6

YEGY

23

OUT 7

GNPK

24

OUT 8

YEPK

25

OUT 9

BNBU

26

OUT 10

BNGN

27

OUT 11

YEBU

28

OUT 12

RDYE

29

OUT 13

BNRD

30

OUT 14

BKBN

31

OUT 15

BN

32
33

GY 0.5 mm2

DC 0 Vext

ERR

ERR

X 17

X 32

X 33

Ausgänge

view onto front panel

connector
INS0523

DEA05.1

X 33

frei

35

0Vext

36
GN 0.5 mm2 DC 24 Vext

ERR

inputs

frei

34

DEA06.1

IN 0

2

DEA05.1

1

DEA04.1

BKGN

frei

37

Uext

Connect shield via cable
grip with metal connector
housing

INK0271

Ferrules for
intermediate clamping

45
200
IKS0123

A07X2X1P.fh5

Fig. 13-1: Terminal Diagram DEA04.1, DEA05.1, DEA06.1

13-2 Input / output interface DEA04.1, DEA05.1, DEA06.1

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

13.3 Technical Data - DEA04.1, DEA05.1, DEA06.1
Designation

Unit

min.

type

max.

Power supply

+Uext

V

18

Current consumption

Iext

A

0.15

Inputs X17/1…15

+UHigh

V

14

+ULow

V

0

& lt; 1

3

+Uhigh

V

Uext-2

Uext-1

Uext

+Ulow

V

0

1,6

IL

mA

0

-

OutputsX17/16…31

24
0.2

32

1)

2.2

24

2)

32

2
80

3)

1) Current consumption of 0.2 A without loading outputs at 24 V
2) Current consumption of 2.2 A, loading all outputs with 80 mA each
3) The lamp control necessitates that the making current is limited by means
of resistance, e.g., 100 R, to 250 mA as otherwise the overcurrent monitor is
actuated and the output locked.
Fig. 13-2: Technical data - DEA04.1, DEA05.1, DEA06.1

Schematic diagram - digital
input and output circuits

Iext

X17
+Uext

DC

8

+12 V
DC
1/4 HEF40244

input

0 Vext

1…15

5K

12V 100nF

35

IL
output

5K

UDN 2987A

16…32

22k

I06X2X1P.fh5

Fig. 13-3: Schematic diagram - digital input and output circuits

Recommended load inductance
circuit

All relays must have free-wheeling diodes. To protect these, an
additional diode is needed as polarity reversal protection.

+
D2

D1

D1: free-wheeling diode
D2: polarity reversal protection

I07X2X1P.fh5

Fig. 13-4: Recommended load inductance circuit

Notes:

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

If driver UND 2987 A has switched off one or more outputs
due to overload, then the error state will be displayed by the
LED which has been switched on.

Input / output interface DEA04.1, DEA05.1, DEA06.1 13-3

Plug-in module for digital intelligent drive controllers

Notes:

13-4 Input / output interface DEA04.1, DEA05.1, DEA06.1

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

14

Input / output interface DEA04.2, DEA05.2, DEA06.2

14.1 General Information
These plug-in modules have 15 inputs and 16 outputs via which the drive
can exchange binary signals with a PLC.
The difference between the three types is the address.
To avoid confusion during installation, the D-subminiature plug-in
connectors are differently labelled.

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Input / output interface DEA04.2, DEA05.2, DEA06.2 14-1

Plug-in module for digital intelligent drive controllers

14.2 Terminal Diagram
Standard
cable IKS0123

X17/X32/X33

GYPK

IN 1

RDGN

3

IN 2

BKYE

4

IN 3

GNBU

5

IN 4

RDBU

6

IN 5

BNYE

7

IN 6

BNGY

8

IN 7

RDWH

9

IN 8

WHPK

10

IN 9

BKWH

11

IN 10

BNPK

12

IN 11

YEWH

13

IN 12

GNWH

14

IN 13

BUWH

15

IN 14

GNGY

16

OUT 0

GYWH

17

OUT 1

WH

18

OUT 2

VT

19

OUT 3

YE

20

OUT 4

PK

21

OUT 5

BU

22

OUT 6

YEGY

23

OUT 7

GNPK

24

OUT 8

YEPK

25

OUT 9

BNBU

26

OUT 10

BNGN

27

OUT 11

YEBU

28

OUT 12

RDYE

29

OUT 13

BNRD

30

OUT 14

BKBN

31

OUT 15

BN

32

CLC_Bb

33

DC 0 Vext

ERR

X 17

X 32

X 33

Outputs

View onto front panel

Connector
INS0523

DEA05.2
X 32

free

35

0Vext

36
GN 0.5 mm2 DC 24 Vext

ERR

Inputs

free

34
GY 0.5 mm2

ERR

DEA06.2

IN 0

2

DEA05.2

1

DEA04.2

BKGN

free

37

Uext

Connect shield via cable
grip with metal connector
housing

INK0271

Ferrules for
intermediate clamping

45
200
IKS0123

A08X2X1P.fh5

Fig. 14-1: Terminal Diagram DEA04.2, DEA05.2, DEA06.2

14-2 Input / output interface DEA04.2, DEA05.2, DEA06.2

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

14.3 Technical Data - DEA04.2, DEA05.2, DEA06.2
Designation

Unit

min.

type

max.

Power supply

+Uext

V

18

Current consumption

Iext

A

0,15

Inputs X17/1…15

+UHigh

V

14

+ULow

V

0

& lt; 1

3

+Uhigh

V

Uext-2

Uext-1

Uext

+Ulow

V

0

1,6

IL

mA

0

-

OutputsX17/16…31

24
0,2

32

1)

2,2

24

2)

32

2
80

3)

1) Current consumption of 0.2 A without loading outputs at 24 V
2) Current consumption of 2.2 A, loading all outputs with 80 mA each
3) The lamp control necessitates that the making current is limited by means
of resistance, e.g., 100 R, to 250 mA as otherwise the overcurrent monitor is
actuated and the output locked.
Fig. 14-2: Technical data - DEA04.2, DEA05.2, DEA06.2

Schematic diagram - digital
input and output circuits

Iext

X17
+Uext

DC

8

+12 V
DC
1/4 HEF40244

input

0 Vext

1…15

5K

12V 10nF

35

IL
output

5K

UDN 2987A

16…32

33k

I08X2X1P.fh5

Fig. 14-3: Schematic diagram - digital input and output circuits

Recommended load inductance
circuit

All relays must have free-wheeling diodes. To protect these, an
additional diode is needed as polarity reversal protection.

+
D2

D1

D1: free-wheeling diode
D2: polarity reversal protection

I07X2X1P.fh5

Fig. 14-4: Recommended load inductance circuit

Note:

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

If driver UND 2987 A has switched off one or more outputs
due to overload, then the error state will be displayed by the
LED which has been switched on.

Input / output interface DEA04.2, DEA05.2, DEA06.2 14-3

Plug-in module for digital intelligent drive controllers

Output CLC_ Bb

Output CLC_Bb is set to high with each edge change of output OUT15.
Output CLC_Bb remains at high for 100ms. If the state of output OUT15
does not change during this time, then output CLC_Bb goes back to low.
If the state of the output OUT15 is altered during this 100 ms period, then
output CLC_Bb is retriggered and remains in the high state.
Retrigger time: 100 ms

Note:

If output CLC_Bb is used, then output OUT15 can no longer
be used as output OUT15 is used to retrigger output CLC_Bb.

Application:
Output CLC_Bb can be used as a kind of " Watchdog " .

160 ms

80 ms

120 ms

60 ms

80 ms

High
output
OUT 15

Low
100 ms

100 ms

100 ms

High
output
CLC_Bb

Low
Retrigger edge change
0

100

200

300

400

500

600

t in ms

S04X2X1P.fh5

Fig. 14-5: Illustration - how output CLC_Bb works

14-4 Input / output interface DEA04.2, DEA05.2, DEA06.2

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

15

Input / output interface DEA28.1, DEA29.1, DEA30.1

15.1 General Information
These plug-in modules have 32 inputs and 24 outputs each and a CLCBb
output. The plug-in modules are inserted into control card CLC-D... (see
illustration below).
Up to three DEAs can be inserted into the CLC-D.... .
The difference between the plug-in modules is their address range and
the designations of their plug-in connections.
To avoid confusion during installation, the plug-in connections have been
labelled differently.

DEA29.1

DEA30.1
DEA30.1

DEA28.1

DEA28.1

DEA29.1

CLC-D
CLC-D02.3

Allocation of the DEAs to the
CLC-D ...

ERR

ERR

ERR

X 72

H4

X 73

X 74

8
X25
TX

X26

X 28

X 27

RX

F02X2X1P.fh5

Fig. 15-1: Allocation of the DEAs to the CLC-D ...

The inputs and outputs are isolated. An external power supply of DC +24
volts must be connected. The power supply input is protected against
polarity reversal.

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Input / output interface DEA28.1, DEA29.1, DEA30.1 15-1

Plug-in module for digital intelligent drive controllers

15.2 Terminal Diagram
Standard cable IKS0159

ERR

ERR

DEA30.1

In 0
In 1
In 2
In 3
In 4
In 5
In 6
In 7
In 8
In 9
In 10
Out 0
Out 1
Out 2
Out 3
Out 4
Out 5
Out 6
Out 7
CLC_Bb
GND
In 11
In 12
In 13
In 13
In 15
In 16
In 17
In 18
In 19
In 20
In 21
Out 8
Out 9
Out 10
Out 11
Out 12
Out 13
Out 14
Out 15
+24 V
GND
In 22
In 23
In 24
In 25
In 26
In 27
In 28
In 29
In 30
In 31
Out 16
Out 17
Out 18
Out 19
Out 20
Out 21
Out 22
Out 23
+Uext
0Vext

DEA29.1

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62

DEA28.1

WH 0.16 mm2
BN 0.16 mm2
GN 0.16 mm2
YE 0.16 mm2
GY 0.16 mm2
PK 0.16 mm2
BU 0.16 mm2
RD 0.16 mm2
BK 0.16 mm2
VT 0.16 mm2
GY/PK 0.16 mm2
YE/BU 0.21 mm2
RD/GN 0.21 mm2
RD/YE 0.21 mm2
BK/GN 0.21 mm2
BK/YE 0.21 mm2
GY 0.21 mm2
BU/PK 0.21 mm2
GY 0.21 mm2
RD/PK 0.21 mm2
WH1 0.5 mm2
BU/RD 0.16 mm2
GN/WH 0.16 mm2
BN/GN 0.16 mm2
YE/WH 0.16 mm2
BN/YE 0.16 mm2
GY/WH 0.16 mm2
BN/GY 0.16 mm2
WH/PK 0.16 mm2
BN/PK 0.16 mm2
BU/WH 0.16 mm2
BU/BN 0.16 mm2
BK/GY 0.21 mm2
BK/PK 0.21 mm2
BK/BU 0.21 mm2
BK/RD 0.21 mm2
BK/BN/WH 0.21 mm2
BK/YE/GN 0.21 mm2
BK/GY/PK 0.21 mm2
BK/RD/BU 0.21 mm2
WH2 0.5 mm2
WH3 0.5 mm2
RD/WH 0.16 mm2
BN/RD 0.16 mm2
BK/WH 0.16 mm2
BK/BN 0.16 mm2
GN/GY 0.16 mm2
YE/GY 0.16 mm2
PK/GN 0.16 mm2
YE/PK 0.16 mm2
GN/BU 0.16 mm2
BK/GN/WH 0.21 mm2
BK/BN/GN 0.21 mm2
BK/YE/WH 0.21 mm2
BK/BN/YE 0.21 mm2
BK/GY/WH 0.21 mm2
BK/BN/GY 0.21 mm2
BK/WH/PK 0.21 mm2
BK/BN/PK 0.21 mm2
BK/BU/WH 0.21 mm2
WH4 0.5 mm2
WH5 0.5 mm2

X72 / X73 / X74

ERR

62 42 21
X 72

X 73

X 74

43 22 1

connector INS0599

X 72

Ferrules for
intermediate clamping INK0598

45

400
IKS0159

View onto
front panel
A09X2X1P.fh5

Connect shield via cable
grip with metal connector
housing
Fig. 15-2: Terminal Diagram DEA28.1, DEA29.1, DEA30.1

15-2 Input / output interface DEA28.1, DEA29.1, DEA30.1

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

15.3 Technical data - DEA28.1, DEA29.1, DEA30.1
Technical Data
Designation

Unit

Power supply

min.

type

+Uext

V

18

Iext

A

0,15

Inputs IN 0…IN 31

+UHigh
+ULow

V
V

14
0

24
& lt; 1

32
3

Outputs
OUT 0...OUT 23
CLCBb

+Uhigh
+Ulow
IL

V
V
mA

Uext-2
0
0

Uext-1
1,6
-

Uext
2
3)
80

Current consumption

24

max.

0,2

1)

32
2,2

2)

1) Current consumption of 0.2 A without loading outputs at 24 V
2) Current consumption of 2.2 A, loading all outputs with 80 mA each
3) The lamp control necessitates that the making current is limited by means
of resistance, e.g., 100 R, to 250 mA as otherwise the overvoltage monitor is
actuated and the output locked.
Fig. 15-3: Technical data - DEA28.1, DEA29.1, DEA30.1
Schematic diagram - digital
input and output circuits

5K

10V

input

0 Vext

Iext
+Uext
UDN 2987A

IL
output
33k

0 Vext

0 Vext

0 Vext

I09X2X1P.fh5

Fig. 15-4: Schematic diagram - digital input and output circuits
Recommended load inductance
circuit

All relays must have free-wheeling diodes. To protect these, an
additional diode is needed as polarity reversal protection.

+
D2

D1

D1: free-wheeling diode
D2: polarity reversal protection

I07X2X1P.fh5

Fig. 15-5: Recommended load inductance circuit

Note:

The driver UND 2987 A limits short-circuit currents to 350mA.
If short-circuit limits exceed 1µs, then the effected output is
closed (lL=0). The other outputs can function. The affected
output remains locked until the power supply has been
switched off and on once.

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Input / output interface DEA28.1, DEA29.1, DEA30.1 15-3

Plug-in module for digital intelligent drive controllers

Note:

Output CLC_ Bb

If driver UND 2987 A has switched off one or more outputs
due to overload, then the error state will be displayed by the
LED which has been switched on.

Output CLC_Bb is set to high with each edge change of output OUT15.
Output CLC_Bb remains at high for 100ms. If the state of output OUT15
does not change during this time, then output CLC_Bb goes back to low.
If the state of the output OUT15 is altered during this 100 ms period, then
output CLC_Bb is retriggered and remains in the high state.
Retrigger time: 100 ms
Application:
Output CLC_Bb can be used as a kind of " Watchdog " .

160 ms

80 ms

120 ms

60 ms

80 ms

0
relevant
bit *

1
100 ms

100 ms

100 ms

High
output
CLC_Bb

Low
Retrigger edge change
0

100

200

300

400

500

* See Function Description

600

t in ms

S05X2X1P.fh5

Fig. 15-6: Illustration - how output CLC_Bb works

15-4 Input / output interface DEA28.1, DEA29.1, DEA30.1

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

16

Position Interface for Square-Wave Signals
DEF01.1 and DEF02.1

16.1 General Information
" Incremental position interface " modules support the acceptance of
square-wave signals to detect measuring systems directly and externally
mounted to machine elements in the drive controller.
The incremental position interfaces DEF01.1 and DEF02.1 for squarewave signals differ in that they react to different address ranges. These
ranges are automatically divided up during the initialization phase to the
inserted position interface.
To avoid confusion during installation, the D-subminiature plug-in
connectors are labelled differently.

DEF01.1

Connector assignment position interfaces for squarewave signals
DEF01.1 = X22
DEF02.1 = X24

DEF02.1

16.2 DEF01.1 and DEF02.1 Connector Assignments

cable (2x1.0+4x2x0.25)C
type: INK 0209

X22/24

GY 1)

Ua2

8

8

Ua2

PK

Ua2

1

1

Ua2

RD

Ua0

3

3

Ua0

BK

Ua0

4

4

Ua0

BN

Ua1

5

5

Ua1

GN

Ua1

6

6

Ua1

7

7

2

2

9

9

10

10

11

11

12

12

13

13

14

14

15

15

WH 12

BN 12

DC 0V ext.
DC +5V ext.

15-pin D-sub
connector INS 0439
(screw mounting)
stock no.: 252 884
1)

X22

X24

0V
+5V

View onto
front panel

Color coding applies to INDRAMAT cable INK 0209
A10X2X1P.fh5

Fig. 16-1: Connector assignment position interface for square-wave signals
DEF01.1 and DEF02.1

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Position Interface for Square-Wave Signals DEF01.1 and DEF02.1 16-1

Plug-in module for digital intelligent drive controllers

16.3 Technical data - DEF01.1 and DEF02.1
Power supply of the external
measuring system

Designation

Unit

min.

type/
value

max.

V

4.75

5

5.25

Output voltage +5 V
Output current - +5 V

mA

250

Fig. 16-2: Power supply of the external measuring system

Voltage level and phase angle input signals

Designation

Unit

Signal voltage

min.

type/value

V

ULow

V

Ua1

°el.

0

Ua2

Phase angle

UHigh

°el.

max.

90

Max. input frequency

2,5
0.5

kHz

1000

Interpolation - signal period

4-fold

Reference point delay t1

ns

Edge distance t2

50

ns

250

Fig. 16-3: Voltage level and phase angle - input signals

360° electrically = one cycle

Ua1
Ua2

t2

Ua0

t1

t1

S06X2X1P.fh5

Fig. 16-4: Schematic diagram - signal paths

+5 V
Uax

Uax
I10X2X1P.fh5

Fig. 16-5: Schematic diagram - input circuit

16-2 Position Interface for Square-Wave Signals DEF01.1 and DEF02.1

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

17

Encoder Interface DFF01.1

17.1 General Information
Plug-in module " Encoder interface DFF01.1 " supports position detection
of measuring systems GDS01.1 / GDM01.1 mounted directly to the
motion machine elements.
Application example:
The single-turn encoder interface DFF01.1 supports the connection of
main shaft encoder GDS01.1 to a digital drive controller and for relaying
encoder signals to other drive controllers.
Application:
• electronic shafts
• synchronization of drives on main shaft encoders
digital drive controllers
Main shaft encoder
GDS 1.1

DFF01.1 DFF01.1 DFF01.1 DFF01.1 DFF01.1

max. 5 drives
cable length max. 5 m
between two drive
controllers
max. cable lengths of all connections: 75 m

B02X2X1P.fh5

Fig. 17-1: Allocation - DFF01.1

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Encoder Interface DFF01.1 17-1

Plug-in module for digital intelligent drive controllers

17.2 Terminal Diagram
GDS 1.1 / GDM 1.1 encoder

1)

1)

X18

GN

2

2

1

PK

3

3

SC-

4

4

0VM

5

5

PRIOR_OUT

6

6
7

SCL
SDO

10 WH

2

RD

7

7

VT

8

8

5

BN

9

9

8

GY

10

10

S+
C+

11

11

0VM

12

12

13

13
14

DFF01.1

6

FS
SDI

12 BN

3

BK

14

4

BU

15

UG
not assigned

15

1

X 18

1

9

shield

connector INS 0439
stock no.: 231 715
DFF 01.1M, X18 IKS 0374

X 19
1)

X19

1)

2

VT

2

2

3

BNWH

3

3

4

WH

4

4

5

BU

5

5

6

RD

6

6

7

BK

7

7

SCL

8

GY

8

8

SDO

9

PK

9

9

10 GN

10

10

S+
C+

11 YE

11

11

0VM

12 BN

12

12

13 GNWH

13

13

14 YEWH

14

14

FS

15 GYWH

15

15

SDI

1

1

1

SC0VM
PRIOR_IN

UG
not assigned

View onto
front panel
1)

Connect shield with
connector housing

shield

connector INS 0519
stock no.: 231 714
IKS 0024

45

stock no.: 215

45

IKS 0374

DFF01.1
DFF01.1

DFF01.1

DFF01.1
X 18

X 18

INS 0439

INS 0519

X 19

X 19

45

26

IKS 0374

INS 0513
INK 0209

IKS 0024
INS 0439

GDS 1.1

A11X2X1P.fh5

Fig. 17-2: Terminal Diagram DFF01.1

17-2 Encoder Interface DFF01.1

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

18

Positioning Module DLC01.1

18.1 General Information
Plug-in module „Single-axis positioning module DLC01.1“ expands the
drive controller to become a stand-alone single-axis positioning control
unit which can be programed with up to 3000 program sets. Each set
describes a motional sequence or a specific state of inputs to be
monitored or outputs to be set.

DLC 1.1

18.2 Terminal Diagram

Programmier- und
Anzeigeeinheit
34

8

33

32

7

34

33

32

Konfektioniertes Kabel
IKS 0745/...
(bei CTA 04.1-N:
max. Länge = 30m
bei CTA 04.1-B:
max. Länge = 10m)

X30
34

34

33

33

32

32

9

4

5

6

1

2

3

X 30

.
.
.
2

0

-

2

2

1

1

1

CL

CTA 04.1-B, Mat.-Nr. 263051
(Anzeige beleuchtet)
CTA 04.1-N, Mat.-Nr. 263052
(Anzeige unbeleuchtet)

X 31

+

2

1

CR

DDS X3/5
DKS X8/4
X31
1

7

RTS

8

CTS

5

5

GND

4

für IDS

TxD

7

300R

RxD

3

8

RS 485

2

3

RS 232

1

2

4

+(Rx-TxD)

6

6

-(Rx-TxD)

9

9

9pol. D-SUB-Stecker INS 0525
Mat.-Nr. 259 759

Blick auf
Frontplatte

+5V
A12X2X1P.fh5

Fig. 18-1: Terminal Diagram DLC01.1

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Positioning Module DLC01.1 18-1

Plug-in module for digital intelligent drive controllers

Terminal diagram - data
interface

DLC01.1
X31
RxD
TxD
GND

PC
(IBM compatible)

Interface RS 232
IKS 046
max. 15 m

2

bn

2

3

ws

3

5

gn

5

4

7

8

8

9

GND

6

7

TxD

4

6

RxD

9

9-pin D-Sub connector

DLC01.1
X31
RxD
TxD
GND

IDS
decade switch unit

Interface RS 232
IKS 047
max. 20 m

2

1

3

2

5

3
4

9

5

9-pin D-sub connector

RxD
TxD
GND
0V
5V

5-pin plug-in screw clamp

A13X2X1P.fh5

Fig. 18-2: Terminal diagram - data interface RS 232

18-2 Positioning Module DLC01.1

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

DLC 1.1

DLC 1.1

DLC 1.1

cable

connector
housing

cable

IKB0001
shield

X31

cable

IKB0001

X31

IKB0001

X31

GND

5

5

(Rx-Tx)+

4

4

4

6

6

6

(Rx-Tx)-

5

Station
no. n

Station
no. 1

Station
no. 32
end connector

INS0597

6

6

6

6

6

4

4

4

4

4

5

5

5

5

5

D-Sub 9 pin

D-Sub 9 pin

300 R

1)

D-Sub 9 pin

2) cable

IKS0166

Connection to drive amplifier
e.g., DKC,DDS,DDC etc.

External user interface

cable

IKS0164

PC

CTA 10
X1

1

+24V

+24V

2

0V

0V

X2

5
4
300 R

6

X3

GND

RxD

(Rx-Tx)+

TxD

(Rx-Tx)-

GND

X..

2
3
4

TxD
RxD
GND

Notes:
1) When connecting just one station, (without IKB0001) a matching
resistor must also be mounted into the interface cable.
Matching resistance 300R - 470R
2) Extension cable
Do not route data transmission cables parallel to power cables.

A14X2X1P.fh5

Fig. 18-3: DLC-RS 485

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Positioning Module DLC01.1 18-3

Plug-in module for digital intelligent drive controllers

Note:

18-4 Positioning Module DLC01.1

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

19

Positioning Module DLC02.1-FW

19.1 General Information
The plug-in positioning module DLC02.1-FW expands the drive controller
to create a stand-alone single-axis positioning NC control unit which can
be programed with up to 3000 programing blocks. Each block describes
one motional sequence or a specific state of inputs to be monitored or
outputs to be set.
Positioning module DLC02.1-FW is only operated with INTERBUS-S
interface module DBS02.2-FW.
INTERBUS-S interface module DBS02.2-FW is inserted into the
positioning module DLC02.1-FW. Once screwed into place with three
bolts, the DBS02.2 and DLC02.1 become one unit.

Note:

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Please note, when disassembling or removing the plug-in
module from the drive controller that the DBS02.2-FW is
connected with the DLC02.1-FW.

Positioning Module DLC02.1-FW

19-1

Plug-in module for digital intelligent drive controllers

DLC 02.1

19.2 Terminal Diagram

Programming and
display unit
34

34

33

33

32

32

Standard cable
IKS 0745/...
(in CTA 04.1-N:
max. length = 30m
in CTA 04.1-B:
max. length = 10m)

X30
34

34

33

33

32

32

7

8

9

4

5

6

1

2

3

CR

+

0

-

X 30

.
.
.

CL

2

2

2

1

1

1

1

CTA 04.1-B, stock no. 263051
(display illuminated)
CTA 04.1-N, stock no. 263052
(display illuminated)

X 31

2

DDS X3/5
DKS X8/4
X31
1
2

7

RTS

8

CTS

5

5

GND

4

für IDS

TxD

7

300R

RxD

3

8

RS 485

2

3

RS 232

1

4

+(Rx-TxD)

6

6

-(Rx-TxD)

9

9

9 pin D-SUB connector INS
0525

View onto
front panel

+5V
A29X2X1P.fh5

Fig. 19-1: Terminal Diagram DLC02.1-FW

19-2 Positioning Module DLC02.1-FW

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

Terminal diagram
- data interface

DLC02.1
X31
RxD
TxD
GND

PC
(IBM compatible)

Data interface RS 232
IKS 046
max. 15 m

2

bn

2

3

ws

3

5

gn

5

4

7

8

8

9

GND

6

7

TxD

4

6

RxD

9

9-pin D-Sub connector

DLC02.1
X31
RxD
TxD
GND

IDS
decade switch unit

interface RS 232
IKS 047
max. 20 m

2

1

3

2

5

3
4

9

9-pin D-Sub connector

5

RxD
TxD
GND
0V
5V

5-pin plug-in screw clamp

A30X2X1P.fh5

Fig. 19-2: Terminal Diagram - data interface RS 232

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Positioning Module DLC02.1-FW

19-3

Plug-in module for digital intelligent drive controllers

DLC02.1

DLC02.1

DLC02.1

cable

connector
housing

cable

IKB0001
shield

X31

cable

IKB0001

X31

IKB0001

X31

GND

5

5

5

(Rx-Tx)+

4

4

4

6

6

6

(Rx-Tx)-

Station
no. n

Station
no. 1

Station
no. 32
end connector

INS0597

6

6

6

6

6

4

4

4

4

4

5

5

5

5

5

D-Sub 9 pin

D-Sub 9 pin

300 R

1)

D-Sub 9 pin

2) cable

IKS0166

Connection to drive amplifier
e.g., DKC,DDS,DDC etc.

External user unit

cable

IKS0164

PC

CTA 10
X1

1

+24V

+24V

2

0V

0V

X2

5
4
300 R

6

X3

GND

RxD

(Rx-Tx)+

TxD

(Rx-Tx)-

GND

X..

2

TxD

3

RxD

4

GND

Notes:
1) If connecting only one station, (without
IKB0001) a matching resistor must be
additionally mounted into the interface cable.
Matching resistance 300R - 470R
2) Extension cable
Data transmission cables may not be routed
paralle with power cables.
A31X2X1P.fh5

Fig. 19-3: SOT - DLC RS 485 with up to 32 stations

19-4 Positioning Module DLC02.1-FW

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

20

High-Resolution Position Interface for Sine Signals
DLF01.1

20.1 General Information
Measuring systems

Plug-in module " High-resolution position interface DLF01.1 " supports the
acceptance of sine signals for position detection of external measuring
systems directly mounted to moving machine elements.
The high-resolution position interface DLF01.1 evaluates measuring
systems with
• sinusoidal current signals (7 ... 11 µAss) or with
• sinusoidal voltage signals (1 Vss).

Switching from current to
voltage signals

By bridging X23/1 and X23/12 in the connector of the DLF01.1-plug-in
module, the DLF01.1 is set to the evaluation of voltage signals.
If there is no such connection, then the DLF01.1 is set to evaluate current
signals.

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

High-Resolution Position Interface for Sine Signals DLF01.1 20-1

Plug-in module for digital intelligent drive controllers

20.2 Terminal diagrams
Terminal diagram for measuring
systems with voltage signals
max. 50 m
52

45

Ø 26

Standard cable IKS 0383

DLF01.1

coupling INS 0451
max. 50 m
52

45

Ø 26

Standard cable IKS 0384

connector INS 0329
X23
BN

5

5

GN 0.25 mm2

7

7

A+

GN

6

6

BN 0.25 mm2

8

8

A-

15

15

GY

8

8

BK 0.25 mm2

6

6

B+

1

RD 0.25 mm2

B-

1

3

BK

4

5
14

3

GY 0.25 mm2

4

4

R+

4

PK 0.25 mm2

3

3

R-

13

RD

5
14

PK

13

X23

WHGN

10

10

WH 1 mm2

10

10

0V

BNGN

12

12

BN 1mm2

12

12

+5V

9

9

11

11

1

1

2

2

1VSS

Measuring
system
e.g.
LIF 181,
LS 186,
LS 486 from

9

9

cable (2x1.0 + 4x2x0.25)C
type: INK 0280 1)

View onto
front panel

15 pin D-SUB connector INS 0439
(screw mounting)

1) Color coding only applies to INDRAMAT cable

A15X2X1P.fh5

INK 280.

Fig. 20-1: Terminal diagram for measuring systems with voltage signals

Signal breakdown of measuring
systems with voltage signals

DLF01.1
1VSS

Fourfold
signal
breakdown
DGA 1.2

DLF01.1
DLF01.1
DLF01.1
S07X2X1P.fh5

Fig. 20-2: Signal breakdown of measuring systems with voltage signals

For further information, see encoder junction DGA01.2 (pg.29-1).

20-2 High-Resolution Position Interface for Sine Signals DLF01.1

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

Terminal diagram for measuring
systems with current signals
max. 30 m 1)
52

45

Ø 26

Standard cable IKS 0129

DLF01.1

coupling INS 0392
max. 30 m 1)
52

45

Ø 26

konf. Kabel IKS 0130

connector INS 0301
GN

9 pin plug-in connector
INS 0392
1
2

1

GN 0.25 mm2

2

BN 0.25 mm2

X23
7

7

5

RD

6

8
15

5

BK 0.25 mm2

6

6

6

RD 0.25 mm2

5

5

14

BU

8
15

YE

14

4

4

3

3

+Ie1
-Ie1
+Ie2
-Ie2
X23

+Ie0
-Ie0

GY

7

7

GY 0.25 mm2

PK

8

8

PK 0.25 mm2

13

13

WH

4

4

WH 1 mm2

10

10

0V

3

BN 1mm2

12

12

+5V

9

9

shield

11

11

1

1

2

2

BN

3
9

9

11µASS

Measuring system
cable (2x1.0 + 4x2x0.25)C
e.g.,
type: INK 0280 2)
LIF 101,
LS 106,
15 pin D-SUB conn. INS 0439
LS 406 from
(screw mounting)
Heidenhain
stock no.: 252 884
1)
2)

Use line driver DGV if cable exceeds 30 m.
Color coding applies to INDRAMAT cable INK 0280.

View onto
front panel

A16X2X1P.fh5

Fig. 20-3: Terminal diagram for measuring systems with current signals

A cable length of & gt; 30m needs line driver DGV01.1 (see pg. 29-6).

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

High-Resolution Position Interface for Sine Signals DLF01.1 20-3

Plug-in module for digital intelligent drive controllers

20.3 Technical data - DLF01.1
Power supply for external
measuring system
Signal form
Resolution

Output voltage X23/12:

DC +5 V (±5%)

Max. load of outputs X23/12:

150

mA

Approximate sinusoidal signals.
The signal periods supplied by the measuring system has a 2048fold
resolution.
A, B, R 1

VSS

A, B

500

kHz

Max. frequency for reference signals:

R

15

kHz

Signal current:

Ie1, Ie2

7…16 µASS

Ie0

2…8

µASS

Max. frequency for meas. sys. signals:

Ie1, Ie2

150

kHz

Max. frequency for reference signals:

Current signals

Signal voltage:
Max. frequency for meas. sys. signals:

Voltage signals

Ie0

15

kHz

Signal input circuit

DLF 1.1

current signal: Ie1+, Ie2+, Ie0+
voltage signal: A+, B+, R+
current signal: Ie1-, Ie2-, Ie0voltage signal: A-, B-, R-

X23
7, 6, 4
1 µH
X23
8, 5, 3
1 µH

10 nF

121 R

+
10 nF

I11X2X1P.fh5

Fig. 20-4: Signal input circuit

Signal duration
360° el.
A, Ie1
0
90° el.
B, Ie2
0

R, Ie0
0
S08X2X1P.fh5

Fig. 20-5: Schematic diagram - signal paths

20-4 High-Resolution Position Interface for Sine Signals DLF01.1

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

21

Profibus Interface DPF02.1/03.1/04.1

21.1 General Information
With a Profibus interface it is possible to connect I/O subassemblies.
The Profibus interface can, e.g., be used with positioning module
DLC01.1-FW enabling the integration of DLC positioning modules into a
Profibus system.
The design of module DPF02.1/03.1/04.1 as a Profibus DP slave module
makes the integration into a Profibus network of the Profibus category DP
as per DIN 19245-3 possible.
Plug-in modules DPF02.1, DPF03.1 and DPF04.1 vary in terms of their
address ranges, connector designations, address selection switch
designation for the Profibus and the designations for the LED displays.
Profibus
interface

Connector

Address
selection
switch

LED displays

DPF02.1

X55

S8, S9

H8

DPF03.1

X56

S10, S11

H9

DPF04.1
X57
S12, S13
Fig. 21-1: Differences - Profibus interface plug-in modules
Bus addresses

LED display
PNO number and machine trunk
file

H10

The participant addresses on the Profibus are set with both BCD coded
rotary switches. Addresses of between 1 and 99 (decimal) may be set on
the plug-in module.
The LEDs H8/H9/H10 glow green if the " Bus is running " .
The „Profibus User Organization (PNO)“ distributes a hexidecimal
number with four places for the machines to be certified. This enables
the Profibus master to allocate equipment trunk files with interface data
to the slave. The plug-in cards DPF02/3/4 receive the numbers 1346.
The relevant machine trunk data file is named DKC31346.GSD. The file
entails, in text form, the parametrization data for the Profibus. It can be
obtained via the Indramat mailbox.
There are type files in this mailbox also (*.200) for the Siemens NC
control units which are not compatible to the Profibus. There are two
variants of these. One is for a DOS configurator, version 4, the other for
Windows configurator, version 5.

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Profibus Interface DPF02.1/03.1/04.1 21-1

Plug-in module for digital intelligent drive controllers

S8 LOW

S12 LOW S13 HIGH

H10 RUN

S10 LOW S11 HIGH

H9 RUN

S9 HIGH

H8 RUN

DPF04.1

DPF03.1

DPF02.1

21.2 Terminal Diagram

X55/56/57
1
2
3
4
5
6
7
8
9

free
free
RxD / TxD -P
CNTR-P
DGND

X55

X56

X57

VP
free
RxD / TxD -N
CNTR-N

View onto
front panel

A32X2X1P.fh5

Fig. 21-2: Terminal Diagram DPF02.1, DPF03.1, DPF04.1

21-2 Profibus Interface DPF02.1/03.1/04.1

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

21.3 Technical Data
Profibus interface

Profibus interface as per DIN 19245, section 1 with cable termination for
cables of category A or B per DIN 19245, section 3.
The Profibus cable is connected at X55, X56 and/or X57. The connector
is generally not part of the overall delivery but must be ordered separately.
The PROFIBUS connectors each contain a switchable matching resistor.
This resistor must be switched at the first and last bus participant. Do not
confuse cores A and B. Terminate as illustrated below.
1

2

1 Switch positions for first and last slave in the Profibus DP.
2 The cable shield must be directly on the bare metal guide.

R04X2X1P.fh5

Fig. 21-3: Bus connection for first and last slave, bus connector INS0450 without
9-pin D-subminiature bushing

1

2

1 Matching resistor is switched off.
2 The cable shield must be directly on the bare metal guide.

R05X2X1P.fh5

Fig. 21-4: Bus connection for all other slaves, bus connector INS0450 without 9pin D-subminiature bushing
1

2

1 Switch position for the first and last slave in the Profibus DP.
2 The cable shield must be directly on the bare metal guide.

R06X2X1P.fh5

Fig. 21-5: Bus connection for first and last slave, bus connector INS0541 with 9pin D-subminiature bushing

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Profibus Interface DPF02.1/03.1/04.1 21-3

Plug-in module for digital intelligent drive controllers

1

2

1 Matching resistor is switched off.
2 The cable shield must be directly on the bare metal guide.

R07X2X1P.fh5

Fig. 21-6: Bus connection for all other slaves, bus connector INS0541 with 9-pin
D-subminiature bushing

The DPF connection must implement a shielded two-core line as per DIN
19245, section 1.
Pre-assigned bits in DPF02

If Profibus interface DPF02.1 is used together with positioning module
DLC01.1-FW, then specific data bits are pre-defined.
Input /
output
Input

Bit
no

Signal

0

parameter

Definition if 1
=

if 0 =

parametrize

Input

1

automatic

automatic

set-up

Input

2

/E-stop

E-stop

OK

Input

3

start

start

Input

4

/stop

run

Input

5

jogging forwards

jogging
forwards

Input

6

jogging
backwards

jogging
backwards

Input

7

clear

clear error

Output

0

/fault

OK

Output

1

set-up

set-up mode

Output

2

automatic

automatic
mode

Output

3

parameter

parametrization
mode

Output

4

automatic
program

stop

error

automatic
program
running
Fig. 21-7: Pre-defined bits - DPF02 with DLC

21-4 Profibus Interface DPF02.1/03.1/04.1

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

22

Profibus Interface DPF05.1-FW

22.1 General Information
Profibus Interface DPF05.1-FW enables the integration of control module
CLC-D into a Profibus system. The design of the module as a Profibus
DP combi slave module makes it possible to integrate into Profibus
networks of the category Profibus DP, Profibus FMS or a mixture as per
DIN19245-3.
The module DPF05.1-FW has been designed as a plug-in module that
can be directly inserted onto the NC control module. Once screwed
together with three bolts, it creates one unit with the CLC-D.

Note:

Other modules can also be inserted onto the DPF05.1-FW
within the system. This is important when disassembling an
removing!

DPF05.1

22.2 Terminal Diagram

X69
1
2

E2

3

X69
E1
E2
E3
E4
0 VL

E1
E3
E4
OVL

4
5

H15
H16

8 LEDs

X68
1
2

Receive/transmit data P
Repeater control signal P
Data reference potential
Bus 5 V

3
4
5
6
7

Receive/transmit data N
Repeater control signal N

8
9

free
RxD / TxD -P
CNTR-P
DGND

X68

VP
free
RxD / TxD -N
CNTR-N

View onto
front panel

A17X2X1P.fh5

Fig. 22-1: Terminal Diagram DPF05.1M-FW

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Profibus Interface DPF05.1-FW

22-1

Plug-in module for digital intelligent drive controllers

22.3 Technical Data
External inputs

The module DPF05.1 makes four hardware inputs (+24V) available.
These inputs can be used in conjunction with the CLC-D if supported by
the relevant firmware. The signal states at these inputs are transmitted
independent of Profibus status (on/off) to the CLC-D, but the Profibus
master can also query them via the PD or FMS channel.
X69

Designation

Input voltage for
high

Input voltage for
low

1

E1

+16 V... +32 V

-0,5 V ... +8 V

2

E2

+16 V... +32 V

-0,5 V ... +8 V

3

E3

+16 V... +32 V

-0,5 V ... +8 V

4

0VL

reference potential 0V

reference potential 0V

Fig. 22-2: Signal assignment for X69 external inputs

Profibus interface

Profibus interface as per DIN 19245, section 1 with cable termination for
cables of category A or B per DIN 19245, section 3.
The Profibus cable is connected at connector X68. This cable is not part
of the general delivery and must be ordered separately.
The PROFIBUS connectors each contain a switchable matching resistor.
This resistor must be switched at the first and last bus participant. Do not
confuse cores A and B. Terminate as illustrated below.

1

2

1 Switch positions for first and last slave in the Profibus DP.
2 The cable shield must be directly on the bare metal guide.

R04X2X1P.fh5

Fig. 22-3: Bus connection for the first and the last slave, bus connector INS0450
without 9-pin D-subminiature bushing

22-2 Profibus Interface DPF05.1-FW

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

1

2

1 Matching resistor is switched off.
2 The cable shield must be directly on the bare metal guide.

R05X2X1P.fh5

Fig. 22-4: Bus connection for all other slaves, bus connector INS0450 without
9-pin D-subminiature bushing

1

2

1 Switch position for the first and last slave in the Profibus DP.
2 The cable shield must be directly on the bare metal guide.

R06X2X1P.fh5

Fig. 22-5: Bus connection for the first and the last slave, bus connector INS0541
with 9-pin D-subminiature bushing

1

2

1 Matching resistor is switched off.
2 The cable shield must be directly on the bare metal guide.

R07X2X1P.fh5

Fig. 22-6: Bus connection for all other slaves, bus connector INS0541 with
9-pin D-subminiature bushing

The DPF connection must implement a shielded two-core line as per DIN
19245, section 1.

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Profibus Interface DPF05.1-FW

22-3

Plug-in module for digital intelligent drive controllers

Note:

22-4 Profibus Interface DPF05.1-FW

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

23

Analog Signal Interface DRF01.1

23.1 General Information
Plug-in module DRF01.1 supports:
• the measurement of voltages via both differential inputs S1/S3 and
S2/S4 for evaluation in the drive controller.

DRF01.1

23.2 Terminal Diagram DRF01.1

15-pin D-SUB connector INS 0439
(screw mounting)
stock no.: 252 884

X36
1

1

2

2

S3

3

3

S4

4

4

GND

5

5

reserved

6

6

GND

7

7

A1

8

8

free

9

9

S1

10

10

S2

11

11

GND

12

12

13

13

GND

14

14

A0

15

15

free

X36

View onto
front panel

DRF01.1

DRF01.1

IKS 0099
45
Ferrules for intermediate
clamping
200

conn. INS 0439

X36

INK 0280

A18X2X1P.fh5

Fig. 23-1: Terminal Diagram DRF01.1

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Analog Signal Interface DRF01.1 23-1

Plug-in module for digital intelligent drive controllers

23.3 Technical data - DRF01.1
Schematic diagram - input
channels S1/S3 and S2/S4

X36
10k/0.1%

S3/S4

10k/0.1%

to
12 bit
ADU

+
+
10k/0.1%

S1/S2

10k/0.1%

c
20k

90k

d
10k
b
10k

+5V
a
G1
G0

7
14
6

10k

MUX
GND
to second
differential amplifier

I12X2X1P.fh5

Fig. 23-2: Schematic diagram - input channels S1/S3 and S2/S4

Setting the amplificaiton

Amplification is set by switching pins 7 and 14 with pin Pin 6 (GND).
If pins 7 and 14 are open, then amplification is set to 2.

Switching connectors X36

Connector
at
Pin 7

X36

MUX
channel

Amplification

Pin 14

free

free

d

2 (default)

free

GND

c

1

GND

free

b

4

GND

GND

a

10

Fig. 23-3: Switching connector X36

23-2 Analog Signal Interface DRF01.1

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

Voltage level and resolution of
input signals

Amplfication

Input
voltage

min.

S1, S2
S3, S4
|S1-S3|
|S2-S4|
Resolution

-10 V
-10 V

-5 V
-5 V

2

S1, S2
S3, S4
|S1-S3|
|S2-S4|
Resolution

-2,5 V
-2,5 V

4

S1, S2
S3, S4
|S1-S3|
|S2-S4|
Resolution
S1, S2
S3, S4
|S1-S3|
|S2-S4|
Resolution

-1 V
-1 V

1

10

Resolution
12 bit

max.
+10 V
+10 V
10 V
10 V

4.88 mV/Bit
+5 V
+5 V
5V
5V
2.44 mV/Bit
+2.5 V
+2.5 V
2.5 V
2.5 V
1.22 mV/Bit
+1 V
+1 V
1V
1V
0.49 mV/Bit

Fig. 23-4: Voltage level and resolution of input signals

Maximum allowable voltage at the differential amplification inputs S1 to
S4 equals |±50 V|.

Note:

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Maximum allowable voltage at the differential amplification
inputs S1 to S4 equals ± 50V.

Analog Signal Interface DRF01.1 23-3

Plug-in module for digital intelligent drive controllers

Note:

23-4 Analog Signal Interface DRF01.1

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

24

Summer Input Interface DSE01.1

24.1 General Information
The additional plug-in module " Summer input interface " DSE01.1 makes
two summer inputs available in addition to the differential inputs for
system configurations of digital AC servo drives with analog interface.
These two summer inputs make it possible to add command values to the
differential inputs at the ANALOG interface.
The drive enable signal is delayed via contacts ERF X40/9, ARF X40/11
(delay can be set), which is relayed to the command communications
module used (DAE/DAA). Removing the drive enable via contact ERF
X40/9, means that the differential input E1/E2 is switched off. The
summer input remains active until the delayed drive enable removal is
completed.
To enable NC control reactions suited to the process in the event of drive
interference (e.g., return motions), error reaction 3 was introduced into the
analog software for drive errors that permit the maintenance of the speed
control loop.
How error reaction 3 works in the event of an error:
• 18 amplifier overtemperature shutdown
• 19 motor overtemperature shutdown
• 33 external power supply failure
• 68 braking error
The following error reaction is conducted:
• The drive fault is signalled to the NC control by opening the „Bb“
contact.
• The drive controller remains ready until the time-delayed drive enable
signal removal is completed via summer input E3/E4.
• Differential inputs E1/E2 are switched off.
• Upon completion of the time delay, the AC servo drive goes torque
free. Any optionally mounted holding brake is applied.
The digital AC servo drive with ANALOG interface with summer input
interface DSE01.1 is thus functionally compatible with analog servo drives
with TDM drive controllers.

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Summer Input Interface DSE01.1 24-1

Plug-in module for digital intelligent drive controllers

Signal path and torque generation with removal of drive enable signal via
the DSE01.1 contact ERF X40/8.

Drive enable
to ERF via 1
control
0

Drive enable 1
DDS int. 0
Speed command 1
via E1/E2
0

Speed command 1
via E3/E4
0

Motor 1
torque
0
1)

Application of 1
holding brake

2)
4)

6)

0

Speed command 1
to zero in the DDS
0
300 ms 5)

400 ms
3)

t/ms

1) The holding brake applies if speed equals less than 10 min-1.
2) Holding brake applies after 400 ms, even if the speed of the motor
equals & gt; 10 min-1.
3) The holding brake releases at same time drive enable applied.
4) Note: 100 ms after holding brake applied, motor goes torque free.
5) Set time via resistor R5 (see notes on start-up).
6) To ensure a safe release of the holding brake, speed command is activated with a
delay of 100 ms.
S09X2X1P.fh5

Fig.24-1: Signal path and torque generation as dependent on drive enable
signal

24-2 Summer Input Interface DSE01.1

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

Setpoint compensation for
differential input E1/E2

DSE01.1

24.2 Terminal Diagram

Setpoint compensation
for summer input E3
P2

Setpoint compensation
for summer input E4

P3

X40

GND analog

P4

1
2

2

A2

3

E1

4

4

E2

E1

5

5

E3

E3

6

6

0VM

7

7

E4

8

± 10 V differential input

A1

3

±10V setpoint output

1

8

0VM

1
A1
A2

E2

Summer input
Reference potential
for summer inputs
Summer input

Drive enable input
Reference potential
Drive enable output

11-pin plug-in screw clamp
MC 1.5 / 10 ST; stock no.: 241 592

0VM
E4

9

9

0VM
ERF
0VM

ERF

ARF

11

10
11

10

0VM

X40

ARF

View onto front panel
F03X2X1P.fh5

Fig. 24-2: Terminal diagram with allocation of terms to DSE01.1

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Summer Input Interface DSE01.1 24-3

Plug-in module for digital intelligent drive controllers

24.3 Technical data - DSE01.1
Analog interface

Designation

Unit

min

max

Input voltage

E1
E2
E3/E4
|E1 - E2|
ERFHIGH

V
V
V
V
V

-10
-10
-10
+3

+10
+10
+10
10
+30

Input current

E1
E2
E3/E4
ERF

mA
mA
mA
mA

-0.5
-0.5
-1

+0.5
+0.5
+1
+2.5

Fig. 24-3: Technical data - analog input circuit

ERF
tx 1)

10 k

ARF
10 k

10 k
E2

-

R2

P2
-

10 k
E1

+

2k

+

A2
A1

10 k
3k
R3

P3

E3
2k
R4

P4

E4
2k
1) tx = settable integral action time

I13X2X1P.fh5

Fig. 24-4: Schematic diagram - analog input circuit

24-4 Summer Input Interface DSE01.1

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

DSE01.1

Plug-in module for digital intelligent drive controllers

1) Connector designation depends on ANALOG interface used
2) E1/E2 differential input for speed setpoint ±10 V
3) E3, E4 two summer inputs for additional setpoints

P2

4) Cascade connection made up of:
• auxiliary contact of the power contactor
• UD contact of the power source
• Bb contact of the drive controller

X13/X15

1)

P3

GND analog

E1
E2

1

TVW
RF
AH

3

Ired1
Ired2
+UI
0VI

2

NC control

2)

4
5
6
7

3)

+24 V±10%
0V

8

4)

SPS

P4

X40

9
10
11

A1
A2

1

A2

E1
E2
E3
0VM
E4
0VM
ERF
0VM
ARF

X40
A1

E1
E
2
E
3
0VM
E4
0VM
ERF
0VM
ARF
11

External
voltage
supplyg
F04X2X1P.fh5

Fig. 24-5: Interconnection DSE01.1 with analog interface and NC control

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Summer Input Interface DSE01.1 24-5

Plug-in module for digital intelligent drive controllers

24.4 Start-Ups
Step 1

DANGER

Step 2

Danger can result from incorrect use of the digital AC
servo drives!
When starting up digital AC servo drives, note the
guidelines in " Application Description " , doc. no.
209-0069-4315.
Additional instructions on starting up plug-in module
DSE01.1 are outlined below.

Speed command value - determining the evaluation via the resistors
• R2 for differential input E1/E2
• R3 for summer input E3
• R4 for summer input E4
It applies:

RX =
RX:
UE:

10k × UE
− 1k
10V

resistane to speed command value evaluation of relevant inputs
rapid input voltage

Fig. 24-6: Determining resistance to speed command value evaluation

• Solder resistors into place, use a maximum tolerance of 1%.
Step 3

Off delay - setting the drive enable signal

Danger to AC servo motors and drive controllers
from overtemperature!
⇒ Set off delay to a maximum of & lt; = 1 seconds.
DANGER

Note:

The OFF delay is standardly set in the TDM to 300ms.

If, for process-compatible actions (e.g., return motions), an OFF delay up
to the deactivation of the speed command values via summer inputs
E3/E4 is needed, then this can be set via resistor R5. To determine the
resistance, see .
To set an OFF delay other than 300 ms, proceed as follows:
1.
2.

24-6 Summer Input Interface DSE01.1

find resistance listed in Fig. 24-7
solder resistance in at soldering point R5

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

R (Ohm)
1M
900 k
800 k
700 k
600 k
500 k
1)

400 k
300 k
200 k
100 k
0
100

200 300

400 500

600

700 800

900

t(ms)

1) Integral action time of drive enable signal set at time of delivery.
K01X2X1P.fh5

Fig. 24-7: Setting resistor R5 to the OFF delay drive enable signal

Step 4

Insert additional plug-in modules in available slot in drive controller.

Note:

Set drive enable in series with „Bb“ contact X3.6/7.

Step 5

Connect DSE card per Fig. 24-5.

Step 6

In menu „Mode/scaling“ of the user interface, set the following
parameters:
• „command default for speed“ to 10 V
• set „speed with command value default“ to rapid traverse speed
• set error reaction 3

Step 7

Danger of accidents due to unwanted drive motions.
⇒ Switch power supply off before compensating voltage.
DANGER
Apply rapid traverse voltage at relevant input and compensate via the
relevant potentiometer to 10 V at X40/A1-A2.
P2 = differential input E1/E2
P3 = summer input E3
P4 = summer input E4

Step 8

Drift compensation of servo axis (see Application Description, sec. 8.2.).

Step 9

Now note the instructions in the Application Description.

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Summer Input Interface DSE01.1 24-7

Plug-in module for digital intelligent drive controllers

X 40 (plug-in bracket
ARF

0 VM

11

10
2
10nF

ZPD 6.2

+

3

10k0

R5
402k

1

+15 V

5
1uF

11 VEE
LM 348N

6

4 VCC

-15 V

49k9

ERF

9

-15 V

2 x 1N4148

+
7
- 348N
LM

1N4148

2 x 100 nF

E4

7

R4
9k09

P4
2k
2.2nF

0 VM
E3

8

5

R3
9k09

P3
2k

10k

2.2nF
100pF
1M
10k
2.2nF
E2
E1

4
3

4k99

2 x 1N4148

13

12
+

4k99
2.2nF

4k99

4k99

LM 348N

2.2nF

A1

D

S

R2
9k09

P2
2k

9

2 x 4393

10

2 x 1N4148

+

8

100R

LM 348N
10k

A2

G
14

3k01

0 VM

100pF

6

2
1

X 1 (plug connector in drive controller)
+15 V

14a
2.2 µF

0 VM

15abc
2.2 µF
13a

-15 V

I14X2X1P.fh5

Fig. 24-8: Current path of the summer input interfaces DSE01.1

24-8 Summer Input Interface DSE01.1

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

25

SERCOS interface DSS01.1

25.1 General Information
The plug-in module " SERCOS interface DSS01.1 " makes it possible to
operate digital drives with SERCOS interface compatible NC control units
via fiber optic cables. It also offers inputs for the evaluation of reference
switches, travel range limit switches and probes.

DSS01.1

25.2 Terminal Diagram

H2

FSMA conn. 2.2 ø INS 0418
6.0 ø INS 0426

H3
CHK

TX
2

3

1

4

0

5

9

6

3

1

4

0

5

9

6

8

X 11 RX

7

X11

LWL interface
receiver

S2 LOW

8

7

2

S3 HIGH

X 10 TX

X10

LWL interface
transmitter

RX

E1
E2

X12

Reference switch
pos. travel range limit switch
neg. travel range limit switch
probe 1
probe 2

1

1

E1

2

2

E2

E3
E4
E5

E4

+UL

5

5

E5

0VL

6

7

7

8

8
9

X 12

E3

4

9

9 pin plug-in screw clamp
stock no.: 241 591

3

4

6

DC +24V ext.
DC 0V ext.

3

+UL
0VL

View onto
front panel
A19X2X1P.fh5

Fig. 25-1: Terminal Diagram DSS01.1

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

SERCOS interface DSS01.1 25-1

Plug-in module for digital intelligent drive controllers

25.3 Technical data - DSS01.1
Voltage level DSS01.1

Designation

Unit

min

type/
value

External voltage supply +UL

V

Current consumption- +UL

18

mA

Inputs

UHigh

V

16

E1…E6

ULow

V

max

24

0

32
100

24

32
5.5

Fig. 25-2: Voltage level DSS01.1

Schematic diagram of digital
input circuits

X12
+UL

7

DC

+12V
DC

Inputs
(E1…E5) 2k74

10K

3k3 12V 100nF

0VL

8

0VTTL
0VL

0VL
I15X2X1P.fh5

Fig. 25-3: Schematic diagram of digital input circuits

Name

Unit

min. 1)

max. 1)

max. transmission power with
opt. low level

PSmaxL

dBm/µW

-31.2/0.75

-28.2/1.5

min. transmission power with
opt. high level

PSminH

dBm/µW

-10.5/90

-7.5/180

max. transmission power with
opt. high level

PSmaxH

dBm/µW

-5.5/280

-3.5/450

λp

nm

640…675 nm (0° to 55° C)

λp

nm

& lt; = 30 nm (25° C)

max. input power for opt. low
level

PEmaxL

dBm/µW

-31.2/0.75

min. input power for opt. high
level

PEminH

dBm/µW

-20/10

max. input power for opt. high
level

Transmitter
data Tx

Abbreviation

PEmaxH

dBm/µW

-5/320

PSminH…PEminH

dB

wave length transmission
diode: peak wave length
spectral bandwidth
Receiverdata Rx

max. attentuation of
transmission path

9.5

12.5

1) Transmission power is set to maximum at delivery. Transmission power can be switched using switch S1.1 on the
SERCOS module board, if necessary.
Fig. 25-4: Technical data - fiber optic cable interface

25-2 SERCOS interface DSS01.1

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

26

SERCOS interface DSS01.3

26.1 General Information
Plug-in module " SERCOS interface DSS01.3 " enables the operation of
digital drives with SERCOS interface compatible controls via fiber optic
cables. It also offers inputs for the evaluation of reference switches, travel
range limit switches, probes and an emergency stop input.

DSS01.3

26.2 Terminal Diagram

H2

FSMA conn. 2.2 ø INS 0418
6.0 ø INS 0426

H3
CHK

TX
2

3

1

4

0

5

9

6

3

1

4

0

5

9

6

8

X 11 RX

7

X11

LWL interface
receiver

S2 LOW

8

7

2

S3 HIGH

X 10 TX

X10

LWL interface
transmitter

RX

E1
E2

X12

Reference switch
pos. travel range limit switch
neg. travel range limit switch
probe 1
probe 2
E-STOP
DC +24V ext.
DC 0V ext.

1

1

E1

2

2

E2

E3
E4
E5

E3

4

E4

+UL

5

5

E5

0VL

6

6

E6

7

7

8

8

+UL
0VL

9

E6

X 12

3

4

9

9 pin plug-in screw clamp
stock no.: 241 591

3

View onto
front panel
A20X2X1P.fh5

Fig. 26-1: Terminal Diagram DSS01.3

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

SERCOS interface DSS01.3 26-1

Plug-in module for digital intelligent drive controllers

26.3 Technical data - DSS01.3
Voltage level DSS01.3

Designation

Unit

min

type/

max

value
External voltage supply +UL

V

18

Current consumption- +UL

mA

Inputs

UHigh

V

17

E1…E6

ULow

V

24

32

0

100
24

32
5.5

Fig. 26-2: Voltage level DSS01.3

Schematic diagram of digital
input circuits

X12
+UL

7

DC

+12V
DC

1/4 HEF40240

Inputs
(E1…E6) 2k74

1/4 PC849

10K

3k3 12V 100nF

0VL

8

0VTTL
0VL

0VL
I16X2X1P.fh5

Fig. 26-3: Schematic diagram of digital input circuits

Name

Unit

min. 1)

max. 1)

max. transmission power with
opt. low level

PSmaxL

dBm/µW

-31.2/0.75

-28.2/1.5

min. transmission power with
opt. high level

PSminH

dBm/µW

-10.5/90

-7.5/180

max. transmission power with
opt. high level

PSmaxH

dBm/µW

-5.5/280

-3.5/450

λp

nm

640…675 nm (0° to.55° C)

λp

nm

& lt; = 30 nm (25° C)

max. input power for opt. low
level

PEmaxL

dBm/µW

-31.2/0.75

min. input power for opt. high
level

PEminH

dBm/µW

-20/10

max. input power for opt. high
level

PEmaxH

dBm/µW

-5/320

max. attentuation transmission
path

Transmitter
data Tx

Abbreviation

PSminH…PEminH

dB

wavelength of transmission
diode: peak wavelength
spectral bandwidth
Receiverdata Rx

9.5

12.5

1) Transmission power is set to maximum at delivery. Transmission power can be switched using switch S1.1 on the
SERCOS module board, if necessary.
Fig. 26-4: Technical data - fiber optic cable interface

26-2 SERCOS interface DSS01.3

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

27

Gear Encoder Interface DZF01.1

27.1 General Information
Plug-in module " Gear Encoder Interface " supports the evaluation of a
high-resolution main spindle position encoder.

27.2 Terminal Diagram
9 pin
plug-in connector
INS0309
61

47

standard cable IKS 0032

DZF 01.1

9 pin
plug-in connector
INS0401
52

45

26

standard cable IKS 0315/..

9 pin
plug-in connector
INS 0401

cable INK 0209
(color designation
per
INDRAMAT standard)

15 pin
D-Subplug-in connector
INS 0439

X20
1

PK 0.25 mm2

2

GY 0.25 mm2

11 0ref

3

GN 0.25 mm2

13 B

4

BN 0.25 mm2

14 Bref

5

BU 0.25 mm2

7 A

6

VT 0.25 mm2

X20

2 0

15 Aref

9

9

7

BN 1 mm2

12 DC +5 Vint

8

WH 1 mm2

10 DC 0 Vint

high resolution
motor feedback
(sensor insulated)

View onto
front panel
A21X2X1P.fh5

Fig. 27-1: Terminal Diagram DZF01.1

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Gear Encoder Interface DZF01.1 27-1

Plug-in module for digital intelligent drive controllers

⇒ The cable to the high-resolution motor feedback
should not be routed over a terminal strip
because of its sensitivity to interference!
WARNING

27.3 Power supply of the external measuring system
Designation

Unit

Output voltage +5 V

V

Output current - +5 V

min.

type/
value

max.

3

5

5.25

mA

200

Fig. 27-2: Power supply of the external measuring system

27-2 Gear Encoder Interface DZF01.1

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

28

Gear Encoder Interface DZF02.1

28.1 General Information
Plug-in module " Gear Encoder Interface " supports the evaluaton of a
high-resolution main spindle position encoder (type SH2 / MH2) and the
feedback of 2AD / ADF motors with feedback type " 3 " .

28.2 Terminal Diagram
DZF02.1

9 pin
plug-in connector
INS0401
52

45

26

standard cable IKS0314/..

9 pin
plug-in connector
INS0401

cable INK0209
(color coded per
INDRAMAT standard)

15 pin
D-Sub
plug-in connector
INS0519

X50
X50

1

PK 0.25 mm2

2

2

GY 0.25 mm2

11 0ref

3

GN 0.25 mm2

13 B

4

BN 0.25 mm2

14 Bref

5

BU 0.25 mm2

7

6

VT 0.25 mm2

15 Aref

9

0

A

9

7

BN 1 mm2

12 DC +5 V

8

WH 1 mm2

10 DC 0 V
1)

high-resolution motor feedback
(sensor insulated)
1)

Connect shield with connector housing via cable grip!

View onto
front panel
A22X2X1P.fh5

Fig. 28-1: Terminal Diagram DZF02.1

⇒ The cable to the high-resolution motor feedback
should not be routed over a terminal strip
because of its sensitivity to interference!
WARNING

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Gear Encoder Interface DZF02.1 28-1

Plug-in module for digital intelligent drive controllers

28.3 Power supply of the external measuring system
Designation

Unit

Output voltage +5 V

V

Output current - +5 V

min.

type/
value

max.

3

5

5.25

mA

200

Fig. 28-2: Power supply of the external measuring system

28-2 Gear Encoder Interface DZF02.1

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

29

Plug-In Module Accessories

29.1 Encoder Branching DGA01.2 for encoders with sinusoidal
1V voltage signals
SS

General Information
With a DGA it is possible to distribute the signals of a measuring system
to up to four measuring systems inputs of different drive controllers.
Possible applications of a DGA are:
• parallel switching of linear motors using one measuring system
• discharge of position signals to external NC controls for monitoring
purposes or as a master axis position.
All measuring systems with sinusoidal output signals and a signal level of
1 VSS can be connected (Heidenhain voltage interface).
Up to four drive controllers can be operated with one DGA. It also has an
output with square signals.
DGA01.2 - schematics of the
connections

1) X2

DLF01.1

X3

DLF01.1

X1 DGA01.2 X4

DLF01.1

X5

DLF01.1

Measuring system:
Linear scale or
rotary encoder

1VSS

ext. control or meas.
system evaluation

X6
1)

Terminal X2 supplies the power
voltage for the DGA and must
always be present.

S10X2X1P.fh5

Fig. 29-1: Schematics of the connections DGA01.2

Standard cables

Connections

Standard cable

of DGA01.2 (X2, X3, X4, X5) to DLF01.1

IKS0131

of DGA01.2 (X6) to DEF01.1

IKS0331

Fig. 29-2: Standard cables

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-In Module Accessories 29-1

Plug-in module for digital intelligent drive controllers

Terminal Diagram
Measuring system, e.g.,
LIF181, LS186, LS468
from Heidenhain

1V
SS

max. processing frequency
fmax = 400 kHz

Max. cable length: 30 m
INS0305

INS0400

X3

X1

5

6

8

1

3

4 10 12

9
INS0301

X6

A+ A- B+ B- R+ R- 0V +5V

Ua0

3

A-

Ua0

4

5

B+

Ua1

5

6

B-

Ua1

6

7

R+

Ua2

8

8

R-

Ua2

1

4

0V

0V

10

3

free

frei

12

incremental encoder

A+

2

to position interface DLF

1

9

9

DGA01.2
INS0400

X5

X4

INS0400
1

A-

A-

2

5

B+

B+

5

6

B-

B-

6

7

R+

R+

7

8

R-

R-

8

4

0V

0V

4

3

free

free

3

2

DLF

A+

9
X2

9

A+ A- B+ B- R+ R- 0V +8V

1

2

5

6

7

8

4

3

DLF

A+

1

9

INS0400
Max. cable length: 75 m

Connection X2 supplies
power for the
DGA and must always be
present.

7

8

6

5

4

3 10

2

1 12

A+ A- B+ B- R+ R- 0V +8V

DLF

A23X2X1P.fh5

Fig. 29-3: Terminal Diagram DGA01.2

29-2

Plug-In Module Accessories

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

Dimensional sheet - DGA01.2
295
80

(60)

175

(60)

1,5

35

65

(60)

X6

X5

55

X1

X2

X4

(60)

7

7

X3

(9)

200

(9)

218

M01X2X1P.fh5

Fig. 29-4: Dimensional sheet - DGA01.2

Technical Data
External measuring system
Power supply for external
measuring system
Signal form

Output voltage X1/12:

DC +5 V (±5%)

Maximum output load X1/12:

150 mA

Approximate sinusoidal signals
Signal voltage:

A, B, R 1

VSS

Max. frequency of meas. sys. signals:

A, B

400

kHz

Max. frequency of reference signal:

Voltage signals

R

15

kHz

Signal input circuits

DGA01.2

voltage signal: A+, B+, R+

voltage signal: A-, B-, R-

X1
5, 8, 3

X1
6, 1, 4

121 R

+

I17X2X1P.fh5

Fig. 29-5: Signal input circuits

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-In Module Accessories 29-3

Plug-in module for digital intelligent drive controllers

Schematic diagram - signal
paths

Signal period
360° el.
A
0
90° el.
B
0

R
0
S11X2X1P.fh5

Fig. 29-6: Schematic diagram - signal paths

Branching - measuring system signals to four terminals
The signals from the measuring system are branched to four terminals,
namely, X2, X3, X4 and X5.
Power supply - DGA01.2

The DGA01.2 receives its power via terminal X2.
Connected voltage X2/3:
Maximum current consumption:

Recommanded signal input
circuit

29-4

Plug-In Module Accessories

DC +8 V (±5%)
300 mA

See Fig. 29-5

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

Output of measuring system signals as square-wave signals
The sinusoidal signals of the measuring systems are output via terminal
X6 in the form of square-wave incremental signals.

Ua2

Ua1
t2

Ua0
t1

t1

S12X2X1P.fh5

Clockwise rotation of encoder shaft
Fig. 29-7: Voltage level and phase angle of the incremental signals

Designation

Unit

min.

type/value

Phase angle Ua1

Grad

0

Phase angle Ua2

Grad

90

Signal amplitude

VSS

max.

7

Ua-(/Ua)
Reference point delay t1

ns

Edge distance t2
ns
Fig. 29-8: Daten zu den Inkrementalsignalen

50
500

Output circuit
Ua1, Ua2, Ua0
X6 (5, 8, 3)

DS 8830 A
X6 (6, 1, 4)
Ua1, Ua2, Ua0
S13X2X1P.fh5

Fig. 29-9: Output circuit

Recommended input circuits

+5V

DS 8820A
STR
TIME
TER
OUT
+
I18X2X1P.fh5

Fig. 29-10: Recommended input circuits

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-In Module Accessories 29-5

Plug-in module for digital intelligent drive controllers

29.2 Line Driver DGV01.1 for Measuring Systems with Current
Signals
Terminal Diagram - Line driver DGV01.1

45

Ø 26

standard cable IKS
52

9 pin plug-in
connector

max. 30 m
Measuring system
e.g., LIF101, LS106,
LS406 from
Heidenhain
+Ie1
-Ie1

GN

15 pin
D-SUB connector
INS 0439
(screw mounting)

INS 0400
Line
driver
DGV 1.1
1

1

2

2

X23
1

GN 0.25
BN 0.25

1

2

2

mm2
mm2

7

7

Ua1+
Ua1-

+Ie2

BK

5

5

5

5

RD

6

6

6

6

RD 0.25 mm2

8
15

6

BK 0.25 mm2

-Ie2

8
15

YE

6

Ua2+
Ua2-

5

5

14
GY

7

7

7

7

GY 0.25 mm2

4

4

Ua0+

-Ie0

PK

8

8

8

8

PK 0.25 mm2

3

3

Ua0-

13

13

0
V
+5V

WH

4

4

4

4

WH 1 mm2

10

10

mm2

BN

2

2

3

3

3

9

9

BN 1

3

9

9

9
1)

shield

11

1

1

12

cable (2x1.0 + 4x2x0.25)C
type: INK 0280 2)

0
V
+8V

9

11

11µAss

2)

X23

14

+Ie0

1)

M

DLF01.1

max. 50 m

12

View onto
front panel

Inside shield on pin 9, outside on connector housing.
Color coding of INDRAMAT cable

A25X2X1P.fh5

Fig. 29-11: Terminal diagram - Line driver DGV01.1

Dimensional sheet - Line driver DGV01.1
295
80

(60)

175

1,5

35

65

(60)

X2

7

7

55

X1

(9)

200

(9)
M02X2X1P.fh5

218

Fig. 29-12: Dimensional sheet - Line driver DGV01.1

29-6

Plug-In Module Accessories

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

30

Index
A

G

ANALOG interface 7-1

Gear Encoder Interface 27-1

Analog Signal Interface 23-1

Ground Reference 4-1

ARCNET Coupler Card 9-1
Areas of Use 1-1

H

C

High-Resolution Position Interface for
Sine Signals 20-1

CLC-D01.1A-FW 5-1

Humidity 2-1

CLC-D02.1A-FW 6-1
CLC-D02.3A-FW 6-1
Control Card 5-1

I
Input / output interface 13-1
INTERBUS-S interface module 10-1

D

INTERBUS-S Slave Module 12-1

DAA01.1 7-1
DAE01.1 8-1
DAK01.1A 9-1
DBS02.1-FW 10-1

L
Line driver 29-6
Low-voltage loops 4-1

DBS02.2-FW 11-1
DBS03.1-FW 12-1
DEA04.1, DEA05.1, DEA06.1 13-1

M

DEA04.2, DEA05.2, DEA06.2 14-1

Metal front plates 3-1

DEA28.1, DEA29.1, DEA30.1 15-1
DEF01.1 and DEF02.1 16-1

O

DFF01.1 17-1
DGA01.2 29-1

Optocoupler Interface 4-1

DGV01.1 29-6
DLC01.1 18-1

P

DLC02.1-FW 19-1

Plastic 3-1

DLF 01.1 20-1

Plug-In Module Accessories 29-1

DPF02.1/03.1/04.1 21-1
DPF05.1-FW 22-1

Position Interface for Square-Wave
Signals 16-1

DRF01.1 23-1

Positioning Module 18-1

DSE01.1 24-1

Profibus Interface 21-1

DSS01.1 25-1
DSS01.3 26-1
DZF01.1 27-1
DZF02.1 28-1

S
SERCOS interface 25-1
Signal inputs 4-1
Signal outputs 4-1

E

Storage 2-1

Earth-Fault Monitoring 4-2
Encoder Branching 29-1
Encoder Interface 17-1

T
Temperature 2-1
Transport Conditions 2-1
Type code 3-2

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Index 30-1

Plug-in module for digital intelligent drive controllers

30-2

Index

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

Directory of Customer Service Locations
Germany
Sales region central

Sales region east

Sales region west

Sales region north

INDRAMAT GmbH
D-97816 Lohr am Main
Bgm.-Dr.-Nebel-Str. 2

INDRAMAT GmbH
D-09120 Chemnitz
Beckerstraße 31

INDRAMAT GmbH
D-40849 Ratingen
Hansastraße 25

INDRAMAT GmbH
D-22085 Hamburg
Fährhausstraße 11

Telefon: 09352/40-0
Telefax: 09352/40-4885

Telefon: 0371/3555-0
Telefax: 0371/3555-230

Telefon: 02102/4318-0
Telefax: 02102/41315

Telefon: 040/227126-16
Telefax: 040/227126-15

Sales region south

Sales region southwest

INDRAMAT Service-Hotline

INDRAMAT GmbH
D-80339 München
Ridlerstraße 75

INDRAMAT GmbH
D-71229 Leonberg
Böblinger Straße 25

INDRAMAT GmbH
Telefon: D-0172/660 040 6

Telefon: 089/540138-30
Telefax: 089/540138-10

Telefon: 07152/972-6
Telefax: 07152/972-727

-orTelefon: D-0171/333 882 6

Customer Service locations in Germany

Europe
Austria

Austria

Belgium

Denmark

G.L.Rexroth Ges.m.b.H.
Geschäftsbereich INDRAMAT
A-1140 Wien
Hägelingasse 3

G.L.Rexroth Ges.m.b.H.
Geschäftsbereich INDRAMAT
A-4061 Pasching
Randlstraße 14

Mannesmann Rexroth N.V.-S.A.
Geschäftsbereich INDRAMAT
B-1740 Ternat
Industrielaan 8

BEC Elektronik AS
DK-8900 Randers
Zinkvej 6

Telefon: 1/9852540-400
Telefax:1/9852540-93

Telefon: 07229/4401-36
Telefax: 07229/4401-80

Telefon: 02/5823180
Telefax: 02/5824310

England

Finnland

France

France

Mannesmann Rexroth Ltd.
INDRAMAT Division
Cirencester, Glos GL7 1YG
4 Esland Place, Love Lane

Rexroth Mecman OY
SF-01720 Vantaa
Riihimiehentie 3

Rexroth - Sigma S.A.
Division INDRAMAT
F-92632 Gennevilliers Cedex
Parc of the Barbanniers 4,
Place du Village

Rexroth - Sigma S.A.
Division INDRAMAT
F-69634 Venissieux - Cx
91, Bd 1 Joliot Curie

Telefon: 01285/658671
Telefax: 01285/654991

Telefon: 0/848511
Telefax: 0/846387

Telefon: 1/41475430
Telefax: 1/47946941

Telefon: 086/447866
Telefax: 086/447160

Telefon: 78785256
Telefax: 78785231

France

Italy

Italy

Netherlands

Rexroth - Sigma S.A.
Division INDRAMAT
F-31100 Toulouse
270, Avenue de lardenne

Rexroth S.p.A.
Divisione INDRAMAT
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DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

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Plug-in module for digital intelligent drive controllers

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DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

Plug-in module for digital intelligent drive controllers

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Plug-in module for digital intelligent drive controllers

Verzeichnis der Kundenbetreuungsstellen

DOK-DIAX02-PLUG*IN*MOD-PRJ1-EN-P

.

Indramat


Indramat Bosch.rar > Serwo Błędy.pdf

engineering

mannesmann
Rexroth

DDS, DKS, DDC and MDD
Digital intelligent AC servo drives
Notes on Fault Clearance
DOK-DIAX02-DDS+DKS+DDC-WAR1-EN-P

259905

Indramat

About this documentation

Titel
Type of documentation:
Documenttype
Internal file reference

DDS, DKS, DDC and MDD - digital intelligent AC servo drives
Notes on Fault Clearance
DOK-DIAX02-DDS+DKS+DDC-WAR1-EN-E1,44
• Mappe 11b
• DDDD-ST.pdf
• 209-0069-4357-01

Reference

This electronic document is based on the hardcopy document with document
desig.: 209-0069-4357-01 EN/ 11.94

This documentation
is used:

It is intended as a quick reference manual for trained maintenance personnel
• to enable rapid identification of fault sources,
• as an effective guide for rapid fault clearance, and,
• for rapid and effective consulting with the machine manufacturer or
INDRAMAT customer service representative.
This manual is intended for storage in the control cabinet where it should be
easily accessible to maintenance personnel.

Supplementary
literature
If a drive component has to be replaced and the machine or plant
subsequently restarted, refer to the relevant Applications Manual
for the installed drive.

An applications manual can be obtained from the nearest service represenative
upon request (see section 3).

Änderungsverlauf

Release-

up to present edition

date

209-0069-4357-01 EN/11.94

Nov./94

First Edition

DOK-DIAX02-DDS+DKS+DDC-WAR1-EN-E1,44

Copyright

Designation of documentation

Coments

Dez./96

Introduction of document type

© INDRAMAT GmbH, 1994
Copying of this document, and giving it to others and the use or communication
of the contents thereof, are forbidden without express authority. 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.

Publisher

Validity

INDRAMAT GmbH • Bgm.-Dr.-Nebel-Straße 2 • D-97816 Lohr
Telefon 0 93 52 / 40-0 • Tx 689421 • Fax 0 93 52 / 40-48 85
Dept ENA (VS, FS)
All rights reserved with respect to the content of this documentation and the
availability of the products.

• DOK-DIAX02-DDS+DKS+DDC-WAR1-EN-E1,44 • 12.96

2

Table of Contents

Table of Contents

Page

1.

General information

5

2.

Status indications

7

2.1.

H1 status indicator (on the drive controller) .....................................7

2.2

H2 status indicator (on SERCOS interface module) ...................... 27

2.3

Command errors ............................................................................30

3.

List of INDRAMAT service representatives

33

4.

Index

35

• DOK-DIAX02-DDS+DKS+DDC-WAR1-EN-E1,44 • 12.96

3

• DOK-DIAX02-DDS+DKS+DDC-WAR1-EN-E1,44 • 12.96

4

1. General information

1.

General information

This manual explains the meanings of the alphanumeric displays on status
indicator H1 (on the drive controller) and H2 (on the SERCOS interface
module). It also helps diagnose any existing problem and quickly clear it.
For quick accessing, all display codes are alphanumerically arranged in the
section " Status Indications " .
In the event that you cannot clear a fault yourself, please contact your
INDRAMAT customer service representative. All addresses are listed in the
section " INDRAMAT customer representatives " .

H1 status indicator
(drive controller)

The H1 status indicator (two-digit seven-segment) on the front of the drive
controller keeps you continuously informed about
• the operating status of the drive,
• faults in the drive controller or cables / conductors,
• faults in the motor,
• faults caused by faulty or invalid parameters, and,
• improper use.

DDC
DDS 2

SYSTEMKONFIGURATION

U5

H1

DDS 3

DKS
U5
S1

H1

U1

U3

U5

SYSTEMKONFIGURATION

1

X9
6
1

X8

U2

U4

U1 U2

X2

7
1

1

X7
10

X3
11

X5
U V W

A1 A2 A3

1

X6
5

X4

PosH1Stör

Figure 1.1: The position of the H1 status indicator
• DOK-DIAX02-DDS+DKS+DDC-WAR1-EN-E1,44 • 12.96

5

1. General information

H2 status indicator
(SERCOS interface
module)

The H2 status indicator (single-digit seven-segment) on the front of the
optional SERCOS interface modules keeps you informed about:
• the operating status of the SERCOS interface module or SERCOS ring,
• faults within the communications via the SERCOS interface, and,
• faults with the SERCOS interface module hardware.

DSS 1.1

DSS SERCOS interface

fault and operating status displayed
H2

3

1

4

0

5

9

6

7 8
2

3

1

4

0

5

9

6

7 8

X 11 RX

S2 LOW

2

S3 HIGH

X 10 TX

H3
CHK

E1
E2
E3
E4

X 12

E5

+UL

looking onto front

FADSSStör

0VL

Figure 1.2: H2 status indicator

• DOK-DIAX02-DDS+DKS+DDC-WAR1-EN-E1,44 • 12.96

6

2. Status indications

2.

Status indications

The display codes of a status indicator are arranged alphanumerically. The
following is available for each code:
• meaning,
• possible causes, and,
• remedial actions (in the case of either faults or warnings)
Displays on H1 (on the drive controller): see section 2.1
Displays on H2 (on the SERCOS interface module): see section 2.2
The power source on the drive controller must be ready to operate
before the status displays can be used for fault diagnostics.

Cancelling a fault

After clearing a fault, it is necessary to first cancel the error message before
the drive can be ready to operate.
An error message is cancelled as follows:
• via the controller, if a SERCOS interface module is used,
• via the fault clearance key " S1 " on the drive, if the ANALOG interface
module is used, and,
• via the fault clerance key " S1 " on the drive, and the " CL " key on the control
unit's control panel if a single-axis positioning module (DLC) is used.

2.1. H1 status indicator (on the drive controller)
Clearing data RAM
(temporary operating status)
Should the drive controller stall in this display, then the drive controller must
be replaced. (See relevant documentation in Applications Manual.)

Checking and, if necessary, automatic clearing of the parameter memory
(EEPROM) in the software module
(temporary operating status)
This is displayed on new software modules for approximately 15 seconds.
Should the drive controller stall in this display, then the drive controller must
be replaced. (See relevant documentation in Applications Manual.)

Loading program
(temporary operating status)
The firmware is loaded into programm memory from EPROM .
Should the drive controller stall in this display, then the drive controller must
be replaced. (See relevant documentation in Applications Manual.)

• DOK-DIAX02-DDS+DKS+DDC-WAR1-EN-E1,44 • 12.96

7

2. H1 status indications (on the drive controller)

Checking Hardware
(temporary operating status)
Checking data RAM.
Should the drive controller stall in this display, then the drive controller must
be replaced. (See relevant documentation in Applications Manual.)

Initializing hardware
(temporary operating status)
Should the drive controller stall in this display, then the drive controller must
be replaced. (See relevant documentation in Applications Manual.)

Initializing software
(temporary operating status)
Data from EEPROM are copied onto the RAM and verified to see whether the
limiting values have been maintained.
Should the drive controller stall in this display, then the drive controller must
be replaced. (See relevant documentation in Applications Manual.)

Initializing the software
(temporary operating status)
(Oscillator functions and feedback codes.)
Should the drive controller stall in this display, then the drive controller must
be replaced. (See relevant documentation in Applications Manual.)

Initializing the software
(temporary operating status)
(reading DSF data)
Should the drive controller stall in this display, then the drive controller must
be replaced. (See relevant documentation in Applications Manual.)

Initializing the SERCOS
(temporary operating status)
Should the drive controller stall in this display, then the drive controller must
be replaced. (See relevant documentation in Applications Manual.)

Watchdog

(fault message)

Cause 1: Software module not installed or defective.
Remedy

Install or replace the software module.

Cause 2: Processor defective.
Remedy

Replace the drive controller.

• DOK-DIAX02-DDS+DKS+DDC-WAR1-EN-E1,44 • 12.96

8

2. H1 status indicator (on the drive controller)

Drive ready
(operating status)
The control and power sections of the drive are ready. Power is on. Drive
enable signal from the NC control unit has not been applied.

Drive enable signal
(operating status)
The drive enable signal has been applied and the drive activated. The drive
will follow the velocity command.

Drive halt
(operating status)
The drive is braked to a stop at the acceleration rate set in the parameters (ID
no. 00136 for SERCOS) and remains under control.

Starting lock-out
(operating status)
The power output stage has been locked. This signal ensures safe torque
disabling of the drive independently of the current operating status of the drive
package (see Applications Manual).

Ready for input power
(operating status)
The control section of the drive is ready for powering up.

E-STOP (Emergency stop)
(operating status)
The E-STOP has been activated. The AC servo drive will be shut down
according to the set error reaction (see Applications Manual).

Park axis command
(operating status)
The NC control unit has issued this command. The drive controller has been
deactivated.

Phase 0
(temporary operating status)
The drive is in Phase 0 and is waiting for phase progression from Phase 0 to
Phase 1. If the drive controller stalls in this display, then there is a problem with
phase progression.
For further diagnostics, please check the definition of the display presently on
H2 (on the SERCOS interface module) in the relevant section of this manual.

Phase 1
(temporary operating status)
The drive is in Phase 1 and is waiting for phase progression from Phase 1 to
Phase 2. If the drive controller stalls in this display, then there is a problem with
phase progression.
For further diagnostics, please check the definition of the display presently on
H2 (on the SERCOS interface module) in the relevant section of this manual.

• DOK-DIAX02-DDS+DKS+DDC-WAR1-EN-E1,44 • 12.96

9

2. H1 status indicator (on the drive controller)

Phase 2
(temporary operating status)
Before the NC control unit progresses to Communications Phase 3, the drive
controller checks the parameters entered for completeness and for compliance
with the input limits (but not for logical accuracy!). If the controller detects any
invalid parameter values, it will prevent progression of the communications
phase.
Does not progress to Phase 3
Remedy

The " ID no. List of Invalid Operation Data for Communications
Phase 2 " (ID no. S-0-0021) contains parameters that are recognized
as invalid prior to transition to Communications Phase 3. These
parameters must be run through before any progression to Phase
3 is possible. Check the parameters.

Phase 3
(temporary operating status)
Before the control unit progresses to Communications Phase 4, the drive
controller checks the parameters entered for completeness and for compliance
with the input limits (but not for logical accuracy!). These parameters must be
run through before any progression to Phase 4 is possible.
Does not progress to Phase 4
Remedy

The " ID no. List of Invalid Operation Data for Communications
Phase 3 " (ID.-Nr. S-0-0022) contains parameters that are recognized
as invalid prior to transition to Communications Phase 4. These
parameters must be run through before any progression to Phase
4 is possible. Check the parameters.

Double MST error shutdown
(fault message)
The drive has not received the master synchronization telegram for two
successive SERCOS cycles.
Cause 1:
Remedy

Check the optical-fiber (LWL) connections in the SERCOS ring.
Check the damping in the LWL cable (maximum damping between
Tx and Rx: 12.5 dB).

Cause 2:
Remedy

Error in the optical-fiber transmission cable, or excessive damping
of optical signals.

Fault in the SERCOS interface module (general).

Replace the SERCOS interface module in the drive package.

Double MST error shutdown
(fault message)
The drive has not received the master synchronization telegram for two
successive SERCOS cycles.
For cause and remedial actions see display " 01 " (double MST error shutdown).

• DOK-DIAX02-DDS+DKS+DDC-WAR1-EN-E1,44 • 12.96

10

2. H1 status indicator (on the drive controller)

Invalid communication phase shutdown
(fault message)
The SERCOS master module has commanded an invalid communication
phase (phase & gt; 4).
Fault in the SERCOS master module of the NC control unit
Remedy

Consult the control unit manufacturer.

Error during phase progression
(fault message)
Phase progression did not comply with the prescribed sequence.
For cause and remedial action see error message " 03 " (invalid communication
phase shutdown).

Error during phase regression
The phase did not revert to Phase 0 during regression.

(fault message)

For cause and remedial action see error message " 03 " (invalid communication
phase shutdown).

Phase progression without ready signal
(fault message)
The SERCOS master attempted to switch phases without waiting for the
drive's " ready " signal.
For cause and remedial action see error message " 03 " (invalid communication
phase shutdown).

Switching to uninitialized operating mode

(fault message)

No operating mode defined in the activated operating mode parameter.
Remedy

Enter the desired operating mode in the activated operating mode
parameter.
See control unit manual for entering the desired operating mode as well as the
parameters S-0-0032 (primary operating mode) and S-0-0033 to S-0-0035
(secondary operating modes 1 through 3) in the SERCOS interface manual.
Permissible operating modes are:









torque loop
velocity loop
position loop with position feedback value 1
position loop with position feedback value 2
position loop with position feedback value 1, lagless
position loop with position feedback value 2, lagless
position loop with command filter with lag error
position loop with command filter, lagless

• DOK-DIAX02-DDS+DKS+DDC-WAR1-EN-E1,44 • 12.96

11

2. H1 status indicator (on the drive controller)

Drive overtemperature shutdown
(fault message)
Overtemperature was detected in the power output stage of the DDS 2.1 drive
controller. The drive controller then emitted a thirty-second warning: 50
" amplifier overtemperature warning " , and shut itself down according to the
selected error reaction, while signalling the above error message.
Cause 1:
Remedy

Replace the drive controller.

Cause 2:
Remedy

Failure of the cabinet air conditioning.

Restore the cabinet air conditioning function.

Cause 3:
Remedy

Failure of internal cooling system of unit.

Incorrectly dimensioned heat dissipation of the cabinet air
conditioning.

Check the cabinet dimensioning.

Motor overtemperature shutdown
(fault message)
The motor temperature has risen above the permissible level. The drive
controller then a emitted a thirty-second warning: 51 " motor overtemperature
warning " . The drive then shut down according to the selected error reaction,
while signalling the above error message (see selection options for error
reactions in the Application Manual).
Cause 1:
Remedy

Check motor dimensioning. For plants which have been in operation
for some time, check whether the drive conditions have changed
(e.g., contamination, friction, moved masses, etc.).

Cause 2:
Remedy

The motor was overloaded. The effective torque demanded from
the motor was above the permissible nominal torque for too long.

Earthing or short-circuit in the conductor for motor temperature
monitoring.

Check the motor temperature monitoring conductor X 6/1 and X 6/2
for earth-short or breaks.

Bleeder overtemperature shutdown

(fault message)

Excessively high continuous regenerative power.
Remedy

Change the process cycle or choose a DKS with a higher rated
current.

• DOK-DIAX02-DDS+DKS+DDC-WAR1-EN-E1,44 • 12.96

12

2. H1 status indicator (on the drive controller)

Motor encoder failure
(fault message)
The signals emitted by the motor encoder are monitored. If the signals lie
outside their tolerance window, the main power will be cut out.
Cause 1:
Remedy

Check feedback cable.

Cause 2:
Remedy

Defective or disconnected encoder cable.

Motor feedback is defective.

If no error can be found on the cable, replace the motor (see relevant
documentation).
Danger of uncontrolled axis motion!
For drives with absolute encoders, make sure to set the right
reference point when changing the motor (refer to Applications
Manual).

Overcurrent

(fault message)

One of the three phase currents has risen to a level higher than 1.5 times the
rated current of the unit.
Remedy

Check the motor cable.
Check the current regulator parameters. Contact an INDRAMAT
service representative.

Overvoltage error
(fault message)
The DC link circuit voltage has risen above the permissible level. (U d & gt; 475 V).
The drive torque has been disabled in order not to risk damaging the power
output stage of the controller.
The energy of a braking main spindle motor could not be converted quickly
enough by the installed bleeder resistors.
Remedy

Reduce the gradient of the braking ramp for the main spindle or
increase bleeder resistance by installing an additional bleeder (see
relevant Applications Manual).

Undervoltage error
(fault message)
The DC link circuit voltage is monitored in the supply module. It signals to the
drive controller via the control voltage bus whether the DC link circuit voltage
exceeds the minimum permissible level of +200. If the voltage falls below this
level, the drive will be shut down according to the selected error reaction. A
prerequisite is that an NCB bridge is not used on the supply module (see
Applications Manual, " Error Reactions " section).
Cause 1:

Remedy

Check the NC control logics for activating the drive.

Cause 2:
Remedy

Mains power shutdown without first deactivating the drive by
cancelling the controller enable signal (RF).

Malfunction of the supply unit

Remedy the malfunction in the power supply unit (see Applications
Manual of the supply unit).

• DOK-DIAX02-DDS+DKS+DDC-WAR1-EN-E1,44 • 12.96

13

2. H1 status indicator (on the drive controller)

Excessive deviation
(fault message)
The drive could not follow the given command value and reacted according to
the selected error reaction.
Cause 1:
Remedy

Check the parameter " bipolar torque limit value " (no. S-0-0092) and
set to the maximum permissible value for the application (see the
section on " Limit Values " in the Applications Manual), or reduce the
acceleration command in the control unit (see the control unit
manual).

Cause 2:
Remedy

S-0-0159 monitoring window incorrectly parametrized.

To check parameter S-0-0159, see section on Operating Modes /
Monitoring of Control Loops in the relevant Applications Manual.

Cause 5:

Remedy

Error in the drive parameters.

Check the drive parameters (see section " Velocity Loop " in the
relevant Applications Manual).

Cause 4:
Remedy

The axis has jammed.

Check the mechanics and remedy any jamming.

Cause 3:
Remedy

The command signal exceeded the acceleration potential of the
drive.

Main power was switched off without the controller enable signal
having been cancelled. Possible cause is an error in one AC servo
drive in the common supply module.

Check AC servo drive for errors other than denoted by message " 28 " .

Travel limit switch is exceeded

(fault message)

The drive has received a command value which would move the axis outside
the permitted travel range.
Remedy

Check position limit parameters S-0-0049 and S-0-0050 (see
Applications Manual, section on " Limit Values " ) or check the software
limits in the control unit.

Command error
(fault message)
Error messages occurring while a command is being executed are displayed
as a collective diagnostic message on the H2 status indicator (32, flashing).
The exact error message can be called up via the SERCOS parameter S-00095 " diagnostic messages " . The definition of all emitted errors is listed in
section 2.3 " Command Errors " .

• DOK-DIAX02-DDS+DKS+DDC-WAR1-EN-E1,44 • 12.96

14

2. H1 status indicator (on the drive controller)

External power supply error
(fault message)
Different optional plug-in modules have DC-decoupled inputs and outputs. An
external power supply must be applied for proper operation of these inputs and
outputs.
The voltage lies above the permissible level.
Remedy

Check the external power supply.
Description

unit

External operating voltage +UL

minimum

V

18

rated
24

mA

Current consumption of external +UL

maximum
32
100

Figure 2.1: Voltage tolerances

Error in internal software synchronization

(fault message)

Faulty communication between the drive's processor and the SERCOS
interface module
Remedy

Replace the SERCOS interface module or the drive controller
(see relevant Applications Manual).

Invalid reference cam position

(fault message)

The position of the reference cam relative to the null point of the motor encoder
is outside the permissible range.
Remedy

For software status ≤ DSM2.1-S01.9:
Parameter P-0-0020 gives the offset of the home switch flank to the
optimum point. Shift the reference cam by this amount, then initiate
a drive-generated homing procedure.
For software status ≥ DSM2.1-S01.10:
Load the value displayed in parameter P-0-0020 into parameter S-00299.

For the tolerance range of the permissible home switch flank positions in the
encoder cycle, see Figure 1.2.:
α cykl Position detection range of one encoder cycle

permissible tolerance range
360°


90°

180°

optimum reference
cam position

180° = 1 α zykl
2

PosRefStör

Figure 2.2: Positioning the reference cam.

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15

2. H1 status indicator (on the drive controller)

Excessive actual position difference
(fault message)
In the prepare phase progression command on Communications Phase 4,
actual position value 2 is stored on the position feedback value, and the
cyclical evaluation of both encoders is initiated. During this cyclical operation
(phase 4), the position difference of both encoders is compared every 8
milliseconds. If the difference is greater than one parametrized monitoring
window (P-0-0120), then error " 36 " appears and the parametrized error
reaction (P-0-0007) is executed.
Cause 1:
Remedy

Check position encoder parameter (S-0-0115) and encoder resolution
(S-0-0117 or S-0-0118).

Cause 2:
Remedy

Maximum input frequency of the encoder interface exceeded.

Reduce velocity.

Cause 7:
Remedy

DEF 1.1 is defective.

Replace DEF 1.1.

Cause 6:
Remedy

The encoder cable is defective.

Replace the encoder cable

Cause 5:
Remedy

The mechanics between motor shaft and external encoder are
not rigid (e.g., gear backlash).

Enlarge monitoring window for external encoder (P-0-0120).

Cause 4:
Remedy

The mechanics between the motor shaft and the external encoder
are incorrectly parametrized.

Check input and output revolutions of load mechanism (S-0-0121, S0-0122) and feed constants (S-0-0123).

Cause 3:
Remedy

The parameter for the external encoder is incorrect (S-0-0115,
S-0-0117, S-0-0118).

External encoder not mounted to running axis.

Set monitoring window for external encoder (P-0-0120) to " 0 " (=
monitoring disengaged).

Excessive position command difference
(fault message)
When the drive is working in position loop mode, position command signals
arriving through the SERCOS interface are monitored.
If the velocity demanded of the drive by two successive position command
signals is equal to or greater than the " bipolar velocity limit value " , the positon
command monitoring function will be activated. The excessive position
command is stored in parameter P-0-0010. The last valid position command
is stored in parameter P-0-0011 (see Applications Manual).
Remedy

Compare the " bipolar velocity limit value " (ID-Nr. S-0-0091) with the
velocity stored in the part program and adapt, if necessary.

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16

2. H1 status indicator (on the drive controller)

External encoder failure: signals too small
(fault message)
For high-resolution evaluation, an external measuring system will use its
analog signals.
The signal amplitudes are below a permissible limit.
Remedy

Check the cable to the measuring system.

Invalid feedback data -- & gt; Phase 2
(fault message)
Error 22 (motor encoder failure) has occurred during cyclic operation (Phase
4). This error message is generated by the drive controller once the first
message has been cleared in Phase 4.
Defective feedback cable or feedback
Remedy

Check feedback and feedback cable, repair/replace, if necessary,
and clear the error in Phase 2.

Travel limit switch detected

(fault message)

The travel limit switch has been detected, resulting in shutdown of the relevant
drive package's power supply. The servo drive was brought to a standstill with
maximum acceleration.
Remedy

1. Clear the error on the control unit.
2. Reactivate the power supply.
3. Move the axis back into the permissible travel range.
Commands that would move the axis still further out of range will not
be accepted by the drive. If it receives another such command, it will
emit the same error message.

External encoder failure: quadrant error
(fault message)
A hardware fault has been detected on the DLF 1.1 high-resolution position
interface for sine signals in the external measuring system.
Cause 1:
Remedy

Replace encoder cable.

Cause 2:
Remedy

Interference in the encoder cable.

Lay encoder cable away from power-carrying cables.

Cause 3:
Remedy

Defective encoder cable.

Defective DLF 1.1 module.

Replace DLF 1.1 module.

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17

2. H1 status indicator (on the drive controller)

External encoder failure:
frequency limit exceeded

(fault message)

The interface module for connection of the external measuring system may
only be operated up to a maximum input frequency.
Maximum input frequencies:
DEF 1.1 = 1000 kHz
DEF 2.1 = 1000 kHz
DLF 1.1
= 150 kHz

Maximum input frequency exceeded.
Remedy

Reduce the velocity.

Error in detecting the marker of the external encoder (fault message)
Cause 1:
Remedy

Defective DLF 1.1 module.

Replace DLF 1.1 module.

Cause 2: Error in detecting the marker of the external encoder.
Remedy

Contact an INDRAMAT service representative as the installed encoder
is not compatible with the evaluation electronics.

Low absolute encoder battery voltage
(fault message/ warning)
Absolute encoders incorporating a battery in the feedback are voltagemonitored. This mesage is emitted if the battery voltage falls below 2.8V. The
absolute encoder will still function for roughly another four weeks.
When this period has elapsed, the absolute reference point may be
lost. This means danger of uncontrolled axis motions! Replace the
battery as soon as possible!

Battery voltage has dropped below 2.8V.
Remedy
Procedure

Replace with new battery (part no. 257101).
The following tools are needed to exchange the battery:
• torx screwdriver, size 10
• pointed pliers
• torque wrench
Danger of uncontrolled axis motions when replacing batteries!
Therefore:
• Switch power supply off. Secure it against being swtiched back on.
• Exchange the battery while the control voltage is on!
If the control voltage is switched off while the battery has been
pulled, then the absolute reference point will be lost.
The absolute reference point must then first be reset.
Removing the old battery:





Using a screwdriver, remove the four torx screws (1).
Manually pull out the lid of the resolver feedback RSF with hood.
Carefully remove the battery plug (2).
Use the pointed pliers to pull the batteries out (3).

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18

2. H1 status indicator (on the drive controller)

Putting the new battery in:
• Manually place the battery (part no. 257101) into the housing. Attention:
do not pinch the battery cable!
• Re-connect the battery plug (2) to the pc board. Attention: make sure
polarity is correct!
• Put lid of the resolver feedback RSF with hood back into the housing.
Attention: Only one lid position is possible!
• Screw the four torx screw (1) back into place and, with the use of the torque
wrench, tighten them with 1.8 Nm.

1
2
3

1

2_03RSF.tif Stör

Figure 2.3: Resolver feedback with back-up battery

Master encoder failure
(fault message)
The master encoder signals are monitored. This error message is generated
when they move out of the tolerance range.
Cause 1:
Remedy

Check the encoder cable.

Cause 2:
Remedy

The feedback is defective.

Replace the feedback.

Cause 3:
Remedy

The encoder cable is faulty.

The DFF card is defective.

Replace the DFF card.

Drive overtemperature warning
(warning)
The temperature of the heatsink in the drive controller has reached the
maximum permissible level. The drive will follow the command value for 30
seconds. This permits the axis to be brought to a halt by the NC control unit
without endangering the process (e.g., completing a machining operation,
retreating from an area where collisions might occur, etc.).
After 30 seconds, the drive will react according to the parameter " error reaction
(P-0-0007) (see relevant Applications Manual).
Cause 1:
Remedy

Replace the drive controller.

Cause 2:
Remedy

Failure of the cabinet's air conditioning system.

Restore the cabinet air conditioning function.

Cause 3:

Remedy

Failure of unit's internal cooling system.

Insufficiently dimensioned cabinet heat dissipation.

Check cabinet dimensioning.

• DOK-DIAX02-DDS+DKS+DDC-WAR1-EN-E1,44 • 12.96

19

2. H1 status indicator (on the drive controller)

Motor overtemperature warning
(warning)
The motor has risen above the permissible temperature. The drive will follow
the given command value for 30 seconds. This permits the axis to be brought
to a halt by the NC control unit without endangering the process (e.g.,
completing a machining operation, retreating from an area where collisions
might occur, etc.). After 30 seconds, the drive will react according to the
parameter " error reaction " (see Applications Manual).
The motor was overloaded. The effective torque demanded from the motor
was above the permissible nominal torque for too long.
Remedy

Check the motor dimensioning. For plants which have been in
operation for some time, check whether the drive conditions have
changed (e.g., contamination, friction, moved masses, etc.).

Bleeder overtemperature warning

(warning)

On reversing, the motor briefly enters the bleeder overload range.
The contact on the plug terminal block X7 closes and can thus be evaluated.
If a predetermined limit is exceeded, error message 20 " bleeder
overtemperature shutdown " will be generated.

Bridge fuse
(fault message)
The current in the power transistor bridge has risen to more than twice the
unit's rated current. The drive torque function is immediately disabled.
Cause 1:
Remedy

Check the motor cable for short-circuits.

Cause 2:
Remedy

Short-circuit in the motor cable.

Power section of the drive controller is defective.

Replace the drive controller, if necessary.

Overcurrent: short to ground
(fault message)
The sum of the phase currents is monitored. During normal operation, the sum
= 0. The earth connection fuse will react when the sum of the currents rises
above 0.5 x IN.
Defective motor cable or earth short in the motor.
Remedy

Check motor cable and motor for shorting to earth and replace, if
necessary (see relevant documentation when replacing).

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20

2. H1 status indicator (on the drive controller)

Erroneous internal hardware synchronization
(fault message)
The pulse width modulator of the drive controller is synchronized by a phase control
loop. The synchronization is monitored and the above error message signalled
when a fault is detected.
Cause 1:
Remedy

Replace the unit and send it in for checking.

Cause 2:
Remedy

Faulty synchronization of the pulse width modulator.

Error in MST from master (NC control unit).

Check transmission starting time. (Consult the manufacturer of the
NC control unit.)

Brake error
(fault message)
For MDD motors with integral brakes, the drive controller pilots the brake. The
brake current is monitored. If it lies outside the permissible range, the above
error message will be signalled.
Cause 1: The supply voltage for the holding brake has not been properly
connected or lies outside the tolerance window (24 V, ±10 %).

Remedy

Remedy

Remedy

Check voltage supply.

Cause 2: Motor cable incomplete or wrongly connected (reverse polarity).
Check motor cable.

Cause 3:

Replace the motor (see relevant documentation).

Cause 4:
Remedy

Defective holding brake.

Defective drive controller.

Replace the controller.

±15 V error

(fault message)

The controller has detected a vault in the ±15 V supply.

Cause 1:
Remedy

Check and, if necessary, replace the control voltage bus cable or plug
connector.

Cause 2:
Remedy

Defective control voltage bus cable.

Defective supply module.

Check the power supply module (see Applications Manual for supply
module).

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2. H1 status indicator (on the drive controller)

+24 V error
The controller has detected a fault in the +24 V supply.
Cause 1:
Remedy

Defective supply module.

Check the power supply module (see Applications Manual for supply
module).

Cause 4:
Remedy

Overload in the 24 V voltage supply.

Check the 24 V voltage supply in the power supply module.

Cause 3:
Remedy

Defective control voltage bus cable.

Check and, if necessary, replace the control voltage bus cable or plug
connector.

Cause 2:
Remedy

(fault message)

Short in the E-stop circuit.

Check the E-stop circuit for shorting.

±10 V error

(fault message)

The supply voltage to the current sensors is faulty.

Defect in the drive controller.
Remedy

Replace the drive controller.

+8 V error
The supply voltage to the encoder systems is faulty.

(fault message)

Short-circuit in motor encoder cable or in cable for external encoders.
Remedy

Check cables and replace, if necessary.

Power supply to driver stage.
The voltage supply to the driver stages is faulty.

(fault message)

Defect in the drive controller.
Remedy

Replace drive controller.

Pattern data transmission time invalid
(fault message)
The pattern calculator is not sending the pattern data synchronously to the
lead axis position.
Remedy

Wrong trigger signals for sending pattern data.
Check trigger signal (consult NC control unit manufacturer).

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2. H1 status indicator (on the drive controller)

Number of transmitted pattern data invalid
Too few or no pattern data have been transmitted.

(fault message)

Cause 1: Faulty connection between pattern calculator and control card.
Remedy

Check the connection between pattern calculator and control card.

Cause 2:
Remedy

Velocity of lead axis is excessive.

Reduce the velocity of the lead axis.

Absolute encoder error
(fault message)
When a DDS with absolute encoder motor (multiturn) is switched off, the
instantaneous actual position is stored. When the unit is powered up again,
this position is compared with the position detected by the absolute encoder
evaluation. If the deviation is outside the parametrized absolute encoder
monitoring window P-0-0097, the above error message is generated and
signalled to the NC control unit.
Cause 1:
Remedy

Initial start-up (stored position invalid).

Clear error (set reference dimensions).

Cause 2:

While shut down, the axis was moved outside the permissible
range as parametrized in the absolute encoder monitoring window
P-0-0097.

Before clearing the fault, check whether a start-up command will
cause any damage.

Remedy

If no damage is possible, then the fault may be cleared.

Cause 3:

Erroneous position initialization (feedback defective).

Danger of uncontrolled axis movement!

Remedy

Check the reference dimension. If this is erroneous, then the feedback
is defective. Replace the motor (see relevant Applications Manual for
replacing motor).

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2. H1 status indicator (on the drive controller)

Velocity loop error
(fault message)
If, when the velocity loop is active, the difference between the velocity
command value and the feedback value is greater than 10% of the maximum
motor speed, the velocity feedback value should alter to approach the
command value. If this has not happened after 10 milliseconds, the system will
shut down while signalling an error to the power supply module.
Cause 1 : Motor cable wrongly connected.
Remedy

Check the motor cable connection.

Cause 2:
Remedy

Replace the drive controller.

Cause 3:
Remedy

Feedback is defective.

Replace the motor (see relevant Applications Manual).

Cause 4:
Remedy

Defective drive controller power section.

Wrong velocity loop parametrization.

Check the velocity loop according to the Applications Manual.

Program RAM error
(fault message)
The memory blocks in the drive controller are checked during initialization. If
an error is detected, the above message will be signalled.
Hardware error in the controller.
Remedy

Replace the controller.

Data RAM error
(fault message)
The memory blocks in the drive controller are checked during initializaton. If
an error is detected, the above message will be signalled.
Hardware error in the drive controller.
Remedy

Replace the drive controller.

Error reading drive data
(fault message)
The operating software reads data from an EEPROM in the drive controller
during initialization. If this is not successful, the above message will be
generated.
Hardware error in the drive controller.
Remedy

Replace the drive controller.

Drive data invalid

(fault message)

Hardware error.
Remedy

Replace the drive controller.

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2. H1 status indicator (on the drive controller)

Error while writing to parameter memory

(fault message)

The parameter memory in the programing module will not accept data.
Remedy

1. Save the parameter set in the programming module.
2. Replace the software module.
3. Transfer the parameter set to the new module.

Parameter data invalid
(fault message)
During the controller initialization phase, one or more parameters in the
software module were found to be invalid.
Cause1:
Remedy

Start the operator interface (see application manual) and call up each
of the submenus in the " PARAMETERS " menu. Invalid parameters
are indicated by " *** " . Enter new parameters for these items.

Cause 2:
Remedy

The software module was not initialized before, or the operating
software EEPROMs in the software module have been changed.

Hardware fault in the software module.

Replace the software module.

Error reading motor data
(fault message)
All motor data are stored in a data memory in the motor feedback. An error has
occurred while reading these data.
Cause 1:
Remedy

Check motor feedback cable and replace, if necessary.

Cause 2:
Remedy

Defective motor feedback cable.

Defective motor feedback.

Replace motor (see relevant replacement documentation).

Motor data invalid

(fault message)

Defective motor feedback.
Remedy

Replace motor (see relevant replacement documentation).

Error while writing motor data
(fault message)
An error has been detected while writing data to the motor feedback.
Cause 1:
Remedy

Check motor feedback cable and replace, if necessary.

Cause 2:
Remedy

Defective motor feedback cable.

Defective motor feedback.

Replace motor (see relevant documentation).

• DOK-DIAX02-DDS+DKS+DDC-WAR1-EN-E1,44 • 12.96

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2. H1 status indicator (on the drive controller)

Configuration error
Cause 1:
Remedy

Software and hardware configurations do not match.

Check the drive controller against its configuration data sheet and
replace software or hardware, if necessary.

Cause 2:
Remedy

(fault message)

Plug-in module defective, not installed or not properly inserted.

Check the plug-in modules.

Absolute encoder not calibrated
(fault message)
The parameter " reference position " and/or " counting direction " in the menu
" ABSOLUTE ENCODER PARAMETER " could not be read.
Cause 1: These parameters have not yet been entered.
Remedy

Enter or confirm parameters.

Cause 2: Defective DSF feedback.
Remedy

Replace motor (see relevant documentation)

DLC watchdog error, no communication with DLC possible
(fault message)
The drive controller monitors that the DLC is operating correctly. If the
processor system of the DLC is out of synchronization with the drive contoller's
processors, error no. 93 will be generated in the DKS.
Defective DLC card.
Remedy

Replace DLC card. If the error is still present after the DLC card has
been replaced, replace the DKS.

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2. H2 status indicator (on the SERCOS interface module)

2.2

H2 status indicator (on SERCOS interface module)

Output power
(operating status)
With the use of the decimal point, it can be determined with what output power
the SERCOS interface module is working.
Decimal point lit up:
Decimal point not lit up:

output power is high (factory setting)
output power is low

If necessary, the output power can be switched via switch S1 on the printed
circuit board of the SERCOS interface module.

EPROM checksum error

(fault message)

The EPROM is faulty.
Remedy

Replace SERCOS interface module.

Invalid communications phase

(fault message)

The NC control unit has attempted to switch into a presently invalid
communications phase.
Remedy

Contact the NC control unit manufacturer.

Error during phase progression

(fault message)

The NC control unit has attempted to switch into a presently invalid
communications phase.
Remedy

Contact the NC control unit manufacturer.

Error during phase regression

(fault message)

The NC control unit has attempted to switch into a presently invalid
communications phase.
Remedy

Contact the NC control unit manufacturer.

No progression to Phase 1
(temporary operating status)
There is an error in phase progression if this value remains displayed.
The NC control unit has not yet triggered progression from Phase 0 to
Phase 1.
Remedy

Refer to NC control unit manual, or contact the manufacturer.

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27

2. H2 status indicator (on the SERCOS interface module)

NC control unit has not yet triggered progression to Phase 2 (temporary
operating status)
There is an error in phase progression if this value remains displayed.
The NC control unit has not yet triggered the progression from Phase 1 to
Phase 2.
Remedy

See control unit manual or contact control unit manufacturer.

Invalid parameters for Phase 3
(fault message)
Before the NC control unit progresses to Communications Phase 3, the drive
controller checks the input parameters for completeness and compliance with
input limits (but not for logical accuracy!). If any invalid parameters are
detected, the controller will prevent any further phase progression.
Parameters for Phase 3 are invalid
Remedy

The " ID no. list of invalid operation data for Communications Phase
2 " , ID no. S-0-0021, contains parameters which the drive recognizes
as invalid prior to progression to Communications Phase 3. These
parameters must be run through before any further phase progression
is possible. Check the parameters.

Invalid parameters for Phase 4
(fault message)
Before the NC control unit switches to Communications Phase 4, the drive
controller checks the input parameters for completeness and compliance with
input limits (but not for logical accuracy!). If any invalid parameters are
detected, the controller will prevent any further phase progression.
Invalid parameters for Phase 4
Remedy

The " ID no. list of invalid operation data for Communications Phase
2 " , ID no. S-0-0021, contains parameters which the drive recognizes
as invalid prior to progression to Communications Phase 4. These
parameters must be run through before any further phase progression
is possible. Check the parameters.

Cyclical operation
(operating status)
The SERCOS ring is in cyclical operation. The communications link within the
SERCOS ring has been successfully established.

Hardware error

(fault message)

General hardware error.
Remedy

Replace SERCOS interface module and/or the drive controller.

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2. H2 status indicator (on the SERCOS interface module)

MST not yet received
(temporary operating status)
No " Master-Sync-Telegram " indicating Communications Phase 0 has yet
been received.
If this value remains displayed, then there is an error in phase progression.
Cause 1:
Remedy

See NC control unit manual or contact manufacturer.

Cause 2:
Remedy

or

Error in phase progression.

Problem with fiber optics cable.

Check fiber optics connections for proper contact and firm fit of
terminal connections.

Test mode

(operating status)

The SERCOS interface has switched to test mode.
Remedy

Contact an INDRAMAT service representative.

Address 0 set

(fault message)

Address 0 has been set on the SERCOS interface module. According to
SERCOS specifications, this is invalid.
Remedy

Set a valid drive address (see NC control unit manual).

Double MDT error
(fault message)
Double master data telegram (MDT) error; will be monitored beginning with
Communications Phase 3.
Cause 1:
Remedy

Check that fiber optic cables are properly connected.

Cause 2:
Remedy

A telegram with an incorrect length was sent.

Checksum error

Replace SERCOS interface module.

Double MST error
(fault message)
Double master synchronization telegram (MST) error; will be monitored
beginning with Communications Phase 3.
Cause 1:
Remedy

Check that fiber optic cables are properly connected.

Cause 2:
Remedy

Fiber optic cable is defective.

The SERCOS interface module in the NC control unit, or in one of
the drive controllers, is defective.

Replace SERCOS interface module.

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29

2. Definition of displays

2.3

Command errors

Error messages generated while commands are being executed are displayed
as a collective diagnostic message on the status indicator H1 (32, flashing).
The respective error message can be called up via the SERCOS parameter
" diagnostic message " S-0-0095.
The various error messages are listed below:

200 Parameter lost

A checksum is stored in the software module for each parameter. When the
drive is initialized, the checksum is calculated again for each parameter and
compared with the stored checksum. In the event of a discrepancy, the above
message will be signalled.

Hardware error in the software module or the drive controller.
Remedy

201 Parameter set
incomplete

1. Save drive parameters.
2. Replace the software module.
3. Transfer the parameters to the new software module.

The parameters stored in the software module are partly invalid.

The installed software module has not been completely parametrized.
Remedy

202 RAM error

Enter the full parameter set. The ID numbers of the invalid operation
data for Communication Phases 2 and 3 are listed in List ID no. S0-0021 and S-0-0022.

The drive controller's read/write memory is not ready.

Hardware error in the drive controller.
Remedy

209 T1 too small:
T1 & lt; T1min
Remedy

210 T2 too large:
T2 +TMTSG & gt; TSCYC
Remedy

Replace the drive controller (see relevant Applications Manual).

The value entered for the parameter " AT transmission starting time " (ID no. S0-0006) is less than T1min (ID no. S-0-0003).
Enter a value that matches the installed NC control unit. (For the
meaning of T1, refer also to the SERCOS interface manual).

The value entered in the parameter " master data telegram transmit starting
time " (ID no. S-0-0089) is too large.
Enter a value that matches the installed NC control unit. (For the
meaning of T2, refer also to the SERCOS interface manual).

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30

2. Definition of displays

211 Master data
telegram too long
Remedy

The value entered in the parameter " length of master data telegram " (ID no.
S-0-0010) is too long.

212 T1 too large:
T1+ TATMT+ AT & gt; T2
Remedy

The value entered in the parameter " AT transmission starting time " (ID no. S0-0006) is too large.

213 T4 too large:
T4 + T4min & gt; TSCYC
Remedy

The value entered in the parameter " feedback acquisition starting time " (ID no.
S-0-0007) is too large.

214 T3 too large:
T3 & gt; TSCYC
Remedy

The value entered in the parameter " command valid time " (ID no. S-0-0008)
is too large.

215 Starting address
in MDT too large
Remedy

The value entered in the parameter " starting address in master data telegram "
(ID no. S-0-0009) is too large.

216 SERCOS cycle
time incorrect
Remedy

The value entered in the parameter " SERCOS cycle time " (ID no.S-0-0002)
is invalid.

219 Starting address
in MDT incorrect
Remedy

The contents of the parameter " starting address in master data telegram " (ID
no. S-0-0009) are incorrect.

243-244 Position
initial error

The position of the motor encoder is calculated when the drive is initialized.
If an error occurs during this calculation, this message will be generated.

Remedy

Enter a value that matches the installed NC control unit (refer also to
the SERCOS interface manual).

Enter a value that matches the installed NC control unit (refer also to
the SERCOS interface manual).

Enter a value that matches the installed NC control unit (refer also to
the SERCOS interface manual).

Enter a value that matches the installed NC control unit (refer also to
the SERCOS interface manual).

Enter a value that matches the installed NC control unit (refer also to
the SERCOS interface manual).

Only whole multiples of 1 ms are valid for the SERCOS cycle time.
Enter a value that matches the installed NC control unit.

Consult the manufacturer of the NC control unit.

Check that the motor feedback cable is correctly connected. If there
is no error in the feedack cable, replace the motor (see relevant
documentation).

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31

2. Definition of displays

250 No absolute
encoder available
Remedy

260 Command error
" travel to dead stop "
Remedy

270 RF missing
during drivegenerated move
command
Remedy

271 No reference
available
Remedy

Status displays
under the SERCOS
interface parameter
" diagnostic
messages " (ID.-Nr. S0-0095)

On attempting to trigger the command " set absolute dimension " , the drive has
detected that the installed motor has no absolute encoder.
If necessary, install a motor with an absolute value encoder, otherwise
suppress the trigger for the command " set absolute dimension " .

An error occurred while the command " travel to dead stop " was being
executed. This causes the drive to shut down.
Look up the error messages of the relevant drive.

The NC control unit has triggered a drive-generated move command (e.g.,
drive-controlled homing cycle), without the drive having been activated prior
to this.
Software error in the NC control unit, since it must first activate the drive before
triggering a drive-controlled move command.
Consult the manufacturer of the NC control unit.

The command " drive controlled homing cycle " has been sent to a motor with
absolute encoder without any marker having been set.
See the Applications Manual, " setting absolute dimensions in drives
with integral absolute encoders " .

300 drive in torque mode
301 drive in velocity mode
302 position mode / encoder 1
303 position mode / encoder 1 / lagless
304 position mode / encoder 2
305 position mode / encoder 2 / lagless
320 Communications Phase 3 transition check
321 Communications Phase 4 transition check
322 set absolute measuring command (P-0-0012)
323 dead stop drive command
330 drive-generated homing command

• DOK-DIAX02-DDS+DKS+DDC-WAR1-EN-E1,44 • 12.96

32

3. List of INDRAMAT service representatives

3.

List of INDRAMAT service representatives

GERMANY
Lohr:
Indramat GmbH
Bgm.-Dr.-Nebel-Str. 2
97816 Lohr am Main
Tel 0 93 52/40-0
Telex 6 89 421
Telefax 0 93 52/40-4885

ENGLAND
G.L. Rexroth Ltd.
Indramat Division
4 Esland Place, Love Lane
Cirencester, Glos GL 7 1 YG
Tel 02 85/65 86 71
Telex 43 565
Telefax 02 85/65 49 91

Chemnitz:
Indramat GmbH
c/o Rexroth Vertriebs- und
Servicegesellschaft mbH
Beckerstraße 31
09120 Chemnitz
Tel 03 71/355-0
Telefax 03 71/355-230

FRANCE
Rexroth - Sigma
Division Indramat
Parc des Barbanniers
4, Place du Village
F - 92 632 Gennevilliers Cedex
Tel 1/47 98 44 66
Telex 616 581
Telefax 1/47 94 69 41

Düsseldorf:
Indramat GmbH
Technisches Büro Ratingen
Harkortstraße 25
Postfach 32 02
40880 Ratingen 1
Tel 0 21 02/44 20 48 /-49
Telefax 0 21 02/41 315

ITALY
Rexroth S.p.A.
Divisione Indramat
Via G. Di Vittorio, 1
I - 20 063 Cernusco S/N. MI
Tel 02/9 23 65 - 270
Telex 331 695
Telefax 02/92 10 80 69

Stuttgart:
Indramat GmbH
Technisches Büro
Liststraße 1/2
71229 Leonberg 1
Tel 0 71 52/25 076/-77
Telefax 0 71 52/25 034

NETHERLANDS
Hydraudyne Hydrauliek B.V.
Kruisbroeksestraat 1a
P.O.Box 32
NL - 5280 AA Boxtel
Tel 04 116/51 951
Telefax 04 116/51 483

AUSTRIA
G.L. Rexroth GmbH
Geschäftsbereich Indramat
Randlstraße 14
A - 4061 Pasching
Tel 07 229/44 01-72
Telefax 07 229/44 01-80

SPAIN
Rexroth S.A.
Centro Industrial Santiga
Obradors s/n
E-08130Santa Perpetua
de Mogoda (Barcelona)
Tel 03/7 18 68 51
Telex 59 181
Telefax 03/718 98 62

DENMARK
BEC Elektronik AS
Zinkvej 6
DK - 8900 Randers
Tel 086/44 78 66
Telefax 086/44 71 60

• DOK-DIAX02-DDS+DKS+DDC-WAR1-EN-E1,44 • 12.96

Goimendi S.A.
División Indramat
Jolastokieta (Herrera)
Apartado 11 37
San Sebastian, 20 017
Tel 043/40 01 63
Telex 36 172
Telefax 043/39 93 95

33

3. List of INDRAMAT service representatives

SWEDEN
AB Rexroth mecman
Indramat Division
Varuvägen 7
S - 125 81 Stockholm
Tel 08/72 79 200
Telefax 08/99 75 15
REPUBLIC OF SLOVENIA
ISKRA Elektromotorji
Otoki 21
YU - 64 228 Zelezniki
Tel 064/66 441
Telex 34 578
Telefax 064/ 67 150
CANADA
Basic Technologies Corporation
Burlington Division
3426 Mainway Drive
Burlington, Ontario
Canada L7M 1A8
Tel 416/335 - 55 11
Telex 06 18 396
Telefax 416/335-41 84
MEXICO
Motorizacion y Diseño de
Controles
Av. Dr. Gustavo Baz No. 288
Col. Parque Industrial la loma
Apartado Postal No. 318
54 060 Tlalnepantla
Estado de Mexico
Tel 5/39 78 64 4
Telefax 5/39 89 88 8
USA
Rexroth Corporation
Indramat Division
255 Mittel Drive
Wood Dale, Illinois 60 191
Tel 708/8 60 - 10 10
Telex 206 582
Telefax 708/5 30 - 46 31
Rexroth Corporation
Indramat Division
2110 Austin Avenue
Rochester Hills, Michigan 48 309
Tel 313/853 - 82 90
Telefax 313/853 - 82 98

• DOK-DIAX02-DDS+DKS+DDC-WAR1-EN-E1,44 • 12.96

ARGENTINA
Mannesmann Rexroth S.A.I.C
Division Indramat
Acassusso 48 41/7
1605 Munro (Buenos Aires)
Argentina
Tel 01/7 56 01 40
01/7 56 02 40
Telex 26 266 rexro ar
Telefax 01/7 56 01 36
BRAZIL
Rexroth Hidráulica Ltda.
Divisão Indramat
Rua Heinrich Passold,130
CP 156
BR - 89. 107-000 Pomerode SC
Tel 04 73/87 03 21
Telex 47 32 88 REXR BR
Telefax 04 73/87 02 51
CHINA
G.L. Rexroth Ltd.
Shanghai Office
Room 206
Shanghai Intern. Trade Centre
2200 Yan Xi Lu
Shanghai 200335
P.R. China
Tel
2755-333
Telefax
2755-666
INDIA
G. L. Rexroth Industries Ltd.
Indramat Division
Plot. 96, Phase III
Peenya Industrial Area
Bangalore - 56 00 58
Tel 80/83 92 10 1
80/83 94 34 5
KOREA
Seo Chang Corporation Ltd.
Room 903, Jeail Building
44 - 35 Yeouido-Dong
Yeongdeungpo-Ku
Seoul, Korea
Tel
02/780 - 82 07 ~9
Telefax 02/784 - 54 08
AUSTRALIA
Australasian Machine Tool
Co. Pty. Ltd.
9 Webber Parade,
East Keilor (Melbourne)
Victoria, 30 33, Australia
Tel 03/336 78 22
Telefax 03/336 17 52

34

4. Index

4.

Index

Symbole
+24 V error 22
+8 V error 22
±10 V error 22
±15 V error 21

A
Absolute encoder error 23
Absolute encoder not calibrated
Address 0 set 29

26

B
Bleeder overtemperature shutdown 12
Bleeder overtemperature warning 20
Brake error 21
Bridge fuse 20

C
Checking and, if necessary, automatic clearing of
Checking Hardware 8
Clearing data RAM 7
Command error 14
Configuration error 26
Cyclical operation 28

7

D
Data RAM error 24
DLC watchdog error, no communication with DLC poss
Double MDT error 29
Double MST error 29
Double MST error shutdown 10
Drive data invalid 24
Drive enable signal 9
Drive halt 9
Drive overtemperature shutdown 12
Drive overtemperature warning 19
Drive ready 9

26

E
E-STOP 9
EPROM checksum error 27
Erroneous internal hardware synchronization 21
Error during phase progression 11, 27
Error during phase regression 27
Error in detecting the marker of the external enco 18
Error in internal software synchronization 15
Error reading drive data 24
Error reading motor data 25
Error while writing motor data 25
Error while writing to parameter memory 25
Excessive actual position difference 16
Excessive deviation 14
Excessive position command difference 16
• DOK-DIAX02-DDS+DKS+DDC-WAR1-EN-E1,44 • 12.96

35

4. Index

External encoder failure: frequency limit exceeded
External encoder failure: quadrant error 17
External encoder failure: signals too small 17
External power supply error 15

18

H
H1 status indicator 5
H2 status indicator 6
Hardware error 28

I
Initializing hardware 8
Initializing software 8
Initializing the SERCOS 8
Invalid communication phase shutdown
Invalid communications phase 27
Invalid feedback data -- & gt; Phase 2 17
Invalid parameters for Phase 3 28
Invalid parameters for Phase 4 28
Invalid reference cam position 15

11

L
Loading program 7
Low absolute encoder battery voltage

18

M
Master encoder failure 19
Motor data invalid 25
Motor encoder failure 13
Motor overtemperature shutdown 12
Motor overtemperature warning 20
MST not yet received 29

N
NC control unit has not yet triggered progression
No progression to Phase 1 27
Number of transmitted pattern data invalid 23

28

O
Output power 27
Overcurrent 13
Overcurrent: short to ground
Overvoltage error 13

20

P
Parameter data invalid 25
Park axis command 9
Pattern data transmission time invalid 22
Phase 0 9
Phase 1 9
Phase 2 10
Phase 3 10
Phase progression without ready signal 11
Power supply to driver stage 22
Program RAM error 24

• DOK-DIAX02-DDS+DKS+DDC-WAR1-EN-E1,44 • 12.96

36

4. Index

R
Ready for input power

9

S
Starting lock-out 9
Switching to uninitialized operating mode

11

T
Test mode 29
Travel limit switch detected 17
Travel limit switch is exceeded 14

U
Undervoltage error

13

V
Velocity loop error

24

W
Watchdog

8

• DOK-DIAX02-DDS+DKS+DDC-WAR1-EN-E1,44 • 12.96

37

Indramat


Indramat Bosch.rar > readme.txt

============================================================================
09.06.2009
DriveTop Fc Version 01V27
Copyright (c) 2009 Bosch Rexroth AG. Alle Rechte vorbehalten.
============================================================================


WICHTIGE INFORMATIONEN :

Systemvoraussetzung
- Pentium PC
- 32 Megabyte RAM
- 15 MB freier Platz auf der Festplatte
- Super VGA Monitor Mindestauflösung von 800 * 600
- Microsoft Windows 95/98/2000/ME/XP/Vista

Unterstützte Frequenzumrichter
- IndraDrive Fc


Indramat Bosch.rar > Serwo montażowa.pdf

engineering

mannesmann
Rexroth

DIAX02
DDS02.1/03.1 Drive Controller Basic Unit
Project Planning Manual
DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-P

274262

Indramat

DDS02.1/03.1

Title

DIAX02
DDS02.1/03.1 Drive Controller Basic Unit

Type of documentation
Document code

Internal file reference

Project Planning Manual
DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97
• Mappe 11a
• DDS_1-PJ.pdf
• 209-0069-4317-02

Reference

Editing sequence

This electronic document based on the hardcopy document with document desig.: DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-P.

Status

Comments

209-0069-4317-01 EN/12.93

Dec. 93

1st edition
DDS02.1

209-0069-4362-00 EN/01.94

Jan. 94

1st edition
DDS03.1

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-P

Jan. 97

rev. edition
DDS02.1/03.1

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44

Copyright

Document designation of previous editions

Apr. 97

E-Doc Release

© INDRAMAT GmbH, 1993
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 for the payment of damages. All rights are reserved
in the event of the grant of a patent or the registration of a utility model or
design (DIN 34-1).
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

INDRAMAT GmbH • Bgm.-Dr.-Nebel-Str. 2 • D-97816 Lohr a. Main
Telefon 09352/40-0 • Tx 689421 • Fax 09352/40-4885
Abt. ENA (JH)
Service-Hotline: Tel. 0172 - 660 040 6 or 0171 - 333 882 6

Validity

All rights are reserved with respect to the content of this documentation
and the availability of the product.

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

DDS02.1/03.1

Contents
1 Introducing the System

1-1

1.1 Individual components of the digital AC servo drive.............................................................................1-2
1.2 Supply units for DDS02.1/03.1 drive controllers...................................................................................1-2

2 Safety guidelines for electrical drives

2-1

2.1 General information..............................................................................................................................2-1
2.2 Guidelines for protection against contact with electrical parts .............................................................2-1
2.3 Guidelines on " protective low voltages " ...........................................................................................2-3
2.4 Guidelines for protection against dangerous movements ....................................................................2-3
2.5 Guidelines for protection when handling and installing ........................................................................2-5

3 DDS02.1/03.1 drive controllers

3-1

3.1 Configured drive controllers .................................................................................................................3-1
3.2 Drive controller, basic unit ....................................................................................................................3-4
Cooling methods............................................................................................................................3-4
Motor feedback..............................................................................................................................3-4
3.3 Software module ..................................................................................................................................3-7
Firmware........................................................................................................................................3-7
3.4 Firmware configuration.........................................................................................................................3-9
3.5 Plugin module.....................................................................................................................................3-10
3.6 Configuration rating plate ...................................................................................................................3-12
3.7 Summary of components fitted in a configuration ..............................................................................3-13

4 Technical data

4-1

4.1 Power section.......................................................................................................................................4-1
4.2 Current consumed during signal processing........................................................................................4-2
4.3 Ambient and environmental conditions ................................................................................................4-4
4.4 Drive controller energy loss..................................................................................................................4-5
Energy loss in the DDS02.1-W......................................................................................................4-5
Energy loss in the DDS02.1-A.......................................................................................................4-6
Energy loss in the DDS02.1-F... ....................................................................................................4-7
Energy loss in the DDS03.1-W......................................................................................................4-8
4.5 Weight ..................................................................................................................................................4-8

5 Planning the construction of the control cabinet

5-1

5.1 Mounting the DDS02.1-W... drive controller.........................................................................................5-4
5.2 Mounting the DDS02.1-A... drive controller..........................................................................................5-5
5.3 Mounting the DDS02.1-F... drive controller ........................................................................................5-10
5.4 Mounting the DDS03.1-W...-. drive controller ....................................................................................5-12

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Contents

I

DDS02.1/03.1

5.5 Interference suppression and EMC....................................................................................................5-13
5.6 Using heat-exchanger units in control cabinets .................................................................................5-13

6 Electrical connections of the drive controller

6-1

6.1 General notes.......................................................................................................................................6-1
6.2 Connecting the basic unit .....................................................................................................................6-2
x Chassis earth connections to the supply unit ............................................................................6-4
yz{ Connecting the motor power cable to the drive controller...................................................6-4
{ Connector X6: Holding brake, motor temperature monitoring..................................................6-7
| DC bus voltage connection........................................................................................................6-7
} Connector X1: Bus connections ................................................................................................6-8
~ Connector X3.............................................................................................................................6-9
 Connector X2: interface RS232...............................................................................................6-11
€ Connector X4: Motor feedback................................................................................................6-12
 Connectors X13, X14a, X14b: heatsink blower only with DDS02.1-A... ..................................6-14
Summary terminal diagram .........................................................................................................6-15
6.3 Connecting the plugin module............................................................................................................6-16

7 Accessories

7-1

7.1 Electrical connecting kit E..-DDS 2.......................................................................................................7-2
7.2 Electrical accessories kit E..-DDS 3.....................................................................................................7-4
7.3 Connector kit for various configurations...............................................................................................7-6
7.4 Service cable - IKS0391.......................................................................................................................7-7
7.5 Selecting the fiber optic cable connections ..........................................................................................7-7
7.6 Mechanical accessories for DDS02.1-A***-*........................................................................................7-8
7.7 Mechanical accessories for DDS02.1-F***-* drive controllers (with liquid cooling) ..............................7-9

8 Powering up the power sections via charging resistors

8-1

9 Condition at delivery

9-1

10 Identifying the merchandise

10-1

11 Storage and transportation

11-1

12 Index

12-1

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Contents

II

DDS02.1/03.1

1

Introducing the System

Inductance
linear motor
LAF

Inductance
linear motor
LAR

Synchronous motor
MKD

Synchronous motor
MDD

UBERSICH.WMF

Fig. 1-1: A digital drive system with DDS

The modular concept makes it possible to flexibly combine AC servo and
main drives to create one compact drive package which uses one supply
unit.
In conjunction with the MDD, MKD and LAR AC motors, the DDS drive
controller is a rapid-response drive. These drives are particularly well
suited for use in machine tool, textile, printing and packaging machinery
as well as robotics and handling machines.

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Introducing the System

1-1

DDS02.1/03.1

1.1

Individual components of the digital AC servo drive
electrical
connect access.

X8

A1

S1
A2
A3
LL+

X1

1

11

plugin module
configured
drive controller
Motor feedback cable
Motor
power cable

AC motor
EKdig

Fig. 1-2: Individual components of the digital AC drive

1.2

Supply units for DDS02.1/03.1 drive controllers
DDS drive controllers can be connected to all INDRAMAT supply units
with a regulated DC 24V voltage.
Note:

Do not operate the DDS with a TVM 1.2 supply unit. The DC
24V of the TVM 1.2 is not regulated.

If TVM 2.1, TVM 2.4 supply units or a KDV 1.3 are used with a DDS drive
controller, then note the information in Section 8 when powering up the
power section via charging resistors. The application descriptions for each
individual supply units must also be noted.

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Introducing the System

1-2

DDS02.1/03.1

2

Safety guidelines for electrical drives
Prior to using the units, please note the following guidelines on personnel
safety.

2.1

General information
• The safety instructions in these user guidelines must be observed at
all times. Improper use of this equipment and disregarding the warnings given here can lead to property damage, cause bodily injury or,
in extreme cases, lead to death.
INDRAMAT is not liable for damages resulting from non-observance of
the warnings given in these operating instructions.
• Documentation in the local language must be obtained prior to commissioning, if the language of the documentation at hand is not understood.
• Proper transport, correct storage, assembly and installation as well as
careful operation are the prerequisites for optimal and safe operation
of this equipment.
• Qualified personnel:
Only appropriately qualified personnel may work on this equipment or
within its vicinity. Personnel are qualified if they have sufficient knowledge of the assembly, installation and operation of the product as well
as of all warnings and safety measures in these operating instructions.
Furthermore, they should be trained, instructed or qualified to switch
electrical circuits and equipment on and off, to earth and label them
according to engineering regulations on safety. They should have adequate safety equipment and be trained in first aid.
• Only use spare parts approved by the manufacturer.
• The safety instructions and regulations for the application must be observed.
• The equipment is designed for installation in machines which are intended for commercial use.
• Start-up is only permitted once it is sure that the machine in which the
products are installed complies with EC directive 89/392/EWG
(machine directives).
• Operation is only permitted if the national EMC directives for the specific application permit it. Within the EU, EMC directive 89/336/EWG
applies.
Guidelines for EMC compliant installation are outlined in the document
" EMC for AC drives and controls“.
Maintaining the national standards is the responsibility of the manufacturer of the machine or plant.
• Technical data, connection and installation conditions are outlined in
the respective product documentation and must be maintained.

2.2

Guidelines for protection against contact with electrical
parts
If live parts with voltages exceeding 50 volts are in any way open to contact, then this could lead to bodily injury. To operate electrical equipment it
is necessary to apply certain parts of it with such dangerous voltages.

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Safety guidelines for electrical drives 2-1

DDS02.1/03.1

DANGER

WARNING

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

High electrical voltages!
Danger to life and risk of injury!
⇒ Observe the general construction and safety guidelines for work on electrial power installations.
⇒ After installation, check that the earth wire is permanently connected to all electrical units as specified in
the connection diagram.
⇒ Operation, even for brief measuring and test purposes, is only permitted when the earth wire is permanently connected to all electrical components.
⇒ Disconnect the equipment from the mains or the voltage source before working on electrical parts with
voltages exceeding 50 volts. Secure the equipment
against being switched back on again.
⇒ Wait five minutes after powering down before starting
work on the equipment. This is due to the capacitors
fitted in the equipment.
⇒ Do not touch the electrical connecting points of a
component while it is switched on.
⇒ Cover live parts properly before switching the equipment on so that no contact is possible.
⇒ Provide protection against indirect contact (as per
DIN EN 50178/ ed. 11/94, section 5.3.2.3).

High discharge current!
Danger to life and risk of serious injury!
⇒ All units and the motor are to be connected to the
earth wire at the earthable point or they must be earthed first before switching on.
⇒ The discharge current exceeds 3.5 mA. A permanent
connection to the supply system is thus required for all
units (as per DIN EN 50178/ ed. 11.94, sect. 5.3.2.3).
⇒ Always connect earth wire before starting up even
when just testing. High voltages could otherwise be
applied to the housing.

Safety guidelines for electrical drives 2-2

DDS02.1/03.1

2.3

Guidelines on " protective low voltages "
The connections on the drive components and interfaces for the signal
voltages range from 5 to 30 volts. These electrical circuits belong to the
safely isolated electrical circuits (protective low voltages).

High electrical voltages from incorrect connections!

WARNING

2.4

Danger of life and limb or serious bodily injury!
⇒ Only those units, electrical components or cables
which have, as per the standards, sufficient and safe
isolation of connected electrical circuits may be attached to the signal voltages (per DIN EN 50178/ ed.
11.94, sect. 5.3.2.3).

Guidelines for protection against dangerous movements
Dangerous movements can occur for various reasons:
• as a result of an incorrect velocity command,
• a software error,
• physical component problems,
• faulty wiring or cable,
• an error in the value or signal encoder and
• incorrect use of components.
These errors can occur just after the equipment is turned on or after an
indefinite period of time.

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Safety guidelines for electrical drives 2-3

DDS02.1/03.1

DANGER

Dangerous movements!
Danger to life and risk of injury or of property damage!
⇒ The drive components monitoring devices make malfunctions in the connected drives almost impossible.
In view of operator safety, however, this cannot be
solely relied upon. An incorrect movement, the size of
which depends on the kind of malfunction and operating status, must in any case be anticipated before the
built-in monitoring devices are activated. Operator
safety must thus be ensured with the use of monitoring devices or measures taken which are superordinate on the plant side. These are provided according
to the specific conditions of the plant after a danger
and error analysis by the plant constructor has been
completed. The safety requirements which apply to
the plant are included here.
⇒ Keep clear of the machine in that area in which movements could occur. Possible measures to take to
prevent access are:
- protective fences
- protective railings
- covers
- light curtains
⇒ Fences and coverings should have sufficient strength
to withstand the maximum possible momentum.
⇒ E-stop switches must be mounted in the immediate
vicinity of an operator for easy reach. Check to make
sure it is functional before starting up.
⇒ Isolate the drive power connection via an emergency
stop circuit or use a starting lockout to protect against
unintentional start ups.
⇒ Make sure that the drives are standing still before accessing or entering the danger zone.
⇒ De-energize electrical equipment using the master
switch and secure against switching on again for:
- maintenance and repair work
- cleaning work
- or prior to long breaks in operation
⇒ Avoid operating high-frequency, remote control and
radio equipment near the equipment electronics and
supply leads. If use of such a unit cannot be avoided,
check the system and the plant for possible malfunctions at all positions of normal use before the first startup. If necesesary, carry out a special EMC test on the
plant.

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Safety guidelines for electrical drives 2-4

DDS02.1/03.1

2.5

Guidelines for protection when handling and installing
Risk of injury during handling!
Bodily injury caused by cruhsing, shearing, cutting and
thrusting movements!
CAUTION

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

⇒ Observe the general construction and safety regulations for handling and installation.
⇒ Use suitable installation and transport equipment in a
proper fashion. If necessary, use special tools.
⇒ Take suitable precautions to prevent pinching and
crushing.
⇒ If necessary, wear suitable protective clothing, for example, protective eyewear, shoes or gloves.
⇒ Do not stand under suspended loads.
⇒ Wipe up liquids spilled onto the floor to prevent slipping.

Safety guidelines for electrical drives 2-5

DDS02.1/03.1

3

DDS02.1/03.1 drive controllers

3.1

Configured drive controllers
The drive controllers are modular in design. The basic unit is adapted to
different functions with the use of various modules. The drive controllers
are delivered by INDRAMAT already configured in terms of the desired
function.
A configured drive controller is made up of both hardware and firmware.
The firmware fixes the functions of the drive controller.
A configured drive controller is made up of:
• basic unit of the drive controller
• plugin modules
• software modules
• firmware (in the software and plugin modules)

Configured DDS02.1-****-****-**FW drive controller

Drive controller basic unit
1

Firmware configuration rating plate

6

S1

A1
H1

U5
FWA-DIAX02-SSE-02VRS-MS
269236

SN269236-02328

K42/96

Soft ware l
u
mod

RS

SYSTEMCONFIGURATION
DDS02.1-W100-DS04-03-FW

U5
L+

DDS02.1-W100-D

X5

U
1 DSS01.3
U
2 DLF01.1

DDS 02.1-W025-D

U
3 COVER

K16/96

SN263498-24321

U COVER
4
U
5 DSM02.1-FW
2

3

0

5

9

6

8

7

2

3

1

0

1

9

7

8

Hardware
configuration
rating plate

X3

6

korrekte
Typenschild
gemäß
Konfigurationsblatt
aufgeklebt sein

5

Achtung
Hier muß das

4

THE CONFIGURATION
TYPE STICKER, WHICH
IS IN ACCORDANCE
WITH THE CONFIGURATION SHEET, MUST
BE PLACED HERE.

rating plate
basic unit

4

ATTENTION

X1

U1 U2 U3 U4
K47/96
1

269973

A01

nd
ma icommun
com n
io
cat dule
mo

U1
11

U2

X4

U3
U4

.
aux in
lug le
p u
d
mo
EKkonfDD

Fig. 3-1: The components of the configured DDS02.1-*** drive controller

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

DDS02.1/03.1 drive controllers

3-1

DDS02.1/03.1

Configured DDS03.1-****-****-**FW drive controller

Drive controller basic unit
X6

Firmware configuration rating plate

U5

1
6

S1

H1

U5
FWA-DIAX02-SSE-02VRS-MS
269236

SN269236-02328

Soft
ware l
u
mod

K42/96

RS

SYSTEMCONFIGURATION
DDS03.1-W030-DS01-02-FW

X5a
L-

DDS03.1-W030-D
U
1 DSS 1.3

L+

U
2 COVER
U COVER
3

X5b

rating plate
basic unit

U COVER
4
U DSM02.1-FW
5
269973

DDS 3.1-W030-D
K30/95

K47/96
SN263508-04604

2

3

1

0

5

9

6

8

7

korrekte
Typenschild
gemäß
Konfigurationsblatt
aufgeklebt sein

X1

U1 U2

Achtung
Hier muß das

TYPE STICKER, WHICH
IS IN ACCORDANCE
WITH THE CONFIGURATION SHEET, MUST
BE PLACED HERE.

4

ATTENTION
THE CONFIGURATION

A00

2

3

1

4

0

5

9

6

and
mm
Co municom ns
io
cat ule
od
m

X2
X3

U1

7

8

Hardware
configuration
rating plate

X4

U2
.
aux in
g
plu ule
d
mo

ekkonfd3

Fig. 3-2: The components of the configured DDS03.1-*** drive controller

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

DDS02.1/03.1 drive controllers

3-2

DDS02.1/03.1

Type codes

Type codes

Example: DDS XX . 1 - X XXX - X X XX - XX - FW

Product group
DDS

DDS

Series
2
3

02
03

Version
1

1

Cooling
Air, control cab. int. air (extern)
Coolant
Air, control cab. ext. air (intern)
Rated current
15A
25A
30A
50A
100A
150A
200A

A 3
F 3
W

015
025
030
050
100
150
200

Motor feedback
Digital servo feedback
Resolver feedback

3
3
3

D
R

Communications module
ANALOG interface
INTERBUS-S interface
Single-axis pos. control
SERCOS interface

1
1
2

A
C
L
S

Function i.d.
determined and documented by INDRAMAT
e.g.: 01

01

Function i.d. version
determined and documented by INDRAMAT
e.g.: 01

01

Firmware
I.d. that firmware is ordered as separate subitem FW

Comment:
1
2
3

only for series " 02 " and cooling " W "
only for series " 03 "
only for series " 02 "

TLDDS2

Fig. 3-3: Type codes of the configured DDS drive controller

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

DDS02.1/03.1 drive controllers

3-3

DDS02.1/03.1

3.2

Drive controller, basic unit
The slots of the basic unit are empty.

Cooling methods
INDRAMAT offers various cooling methods for the DDS02.1 drive controllers (see Fig. 3-4) .
Cooling methods:
• heat technology (cooling airflow inside the control cabinet)
• cold technology (cooling airflow outside the control cabinet)
• liquid cooling
Heat Technology

Units implementing heat technology dissipate heat within the control cabinet.
Consequentially:
• large control cabinet
• air conditioning may be needed
This requires the least amount of mounting and installation efforts.

Cold technology, liquid cooling

These units have the advantage that a large part of the heat is lost outside the control cabinet. As a result, these units can be mounted in small
cabinets or housing.
Units with liquid cooling offer the additional advantage of regaining lost
energy.

Motor feedback
There are, independent of the rated current, two types of drive controllers (basic units). Only motors with Digital Servo Feedback
(DSF) can be connected to the one type and only motors with Resolver feedback (RSF) (see Fig. 3-5 „Motor feedback“) can be connected
at X4 of the other type.

Note:

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

When selecting the motor/controller combination make sure
that the motor feedback data type codes of motor and drive
controller agree.

DDS02.1/03.1 drive controllers

3-4

DDS02.1/03.1

Cooling methods

power dissip.
Mounting
panel

Heat technnology

DDS 2.1 - W . . .

power dissip.

ca.20%

ca.80% power dissip.

Cold technology

DDS 2.1 - K . . .
control cabinet back

power dissip.
ca.20%

DDS 2.1 - F . . .

Mounting panel

liquid cooling

KUEHLART

ca.
80%

power dissip.
Fig. 3-4: Cooling methods in DDS02.1 drive controller illustrated

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

DDS02.1/03.1 drive controllers

3-5

DDS02.1/03.1

Type codes

Type codes

Example: DDS X . X - X XXX - X

Product group
DDS

DDS

Series
2
3

02
03

Version
1

1

Cooling
Air, from outside control cab. (extern)
Coolant
Air, from inside control cab. (intern)

Motor feedback
Digital servo feedback
Resolver feedback

3
3

015
025
030
050
100
150
200

Rated current
15A
25A
30A
50A
100A
150A
200A

A
F
W

1
1
2
3
3
3

D
R

Comments:
1 only for series " 02 " and cooling " W "
2 only for series " 03 "
3 only for series " 02 "

typgrdds

Fig. 3-5: Type codes of the DDS basic unit

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

DDS02.1/03.1 drive controllers

3-6

DDS02.1/03.1

3.3

Software module
Different functions require different software modules. The software module contains both firmware and drive parameters. The software module
needed depends on the selected hardware configuration and the functions of the drive.
The software module guarantees that if the unit needs to be replaced, the
already entered parameters can be carried over to the new unit.
Type codes

shipping date
week/year

unit type

part no.

FWA-DIAX02-SSE-02VRS-MS
269236

barcode

SN269236-02328

K42/96

RS

serial number

Firmware release
status
TYPFWA

Fig. 3-6: Software module type codes

Barcode

Software
module type

Serial number

DSM02.1-FW

DSM 2.1
FWC-DIAX02-SSE-02VRS-MS
266234
K35/96

Abbrev.
Firmware type

DDSSER17

Fig. 3-7: Rating plates on the software module

Firmware
The functional features of the drive controllers are fixed by the firmware.
The firmware must be ordered as a separate item. This means that it is
always possible to reorder the same firmware version.
The firmware is continuously being updated to function more accurately
without, however, changing the functions. This designation is indicated in
the type code as the firmware release status.
If new functions are added, then the index number of the firmware version
is increased (see Fig. 3-8) .

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

DDS02.1/03.1 drive controllers

3-7

DDS02.1/03.1

Type codes

Type codes

Example: FW C - DIAX02 - SSE - 02 V RS - MS

Category
Firmware

FW

Class
PCB

C

Product name
Product: DIAX02

DIAX02

Firmware type (alpha-numeric)
SERCOS interface
Firmware version (01...99)
02
Character of firmware
Test version
Standard

SSE

02

T
V

Firmware Release Status (Update)
The most current status
is delivered.

RS

Language (abbrev.
see INN 09.04, sect. 1-1)
multilingual

MS

TYPFW

Fig. 3-8: Firmware type codes

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

DDS02.1/03.1 drive controllers

3-8

DDS02.1/03.1

3.4

Firmware configuration
The firmware configuration identifies which firmware is used in the configured drive controller.
This means that the firmware configuration is used to determine which
firmware the software module has and, if applicable, which firmware is in
a plugin module. The rating plate of the firmware configuration is on the
face plate.

Type codes

Example: FW A - DIAX02 - SSE - 02 V RS - MS

Category
Firmware

FW

Class
Product

A

Product name
Product: DIAX02

DIAX02

Firmware type (alpha-numeric)
SERCOS interface
Firmware version (01...99)
02
Character of firmware
Test version
Standard

SSE

02

T
V

Firmware Release Status (Update)
Updated version delivered.

RS

Language (abbreviation
see INN 09.04, sect. 1-1)
Multilingual

MS

TYPFWAK

Fig. 3-9: Firmware configuration type codes

shipping date
week/year

unit type

part no.

FWA-DIAX02-SSE-02VRS-MS
269236

barcode

SN269236-02328

serial number

K42/96

RS

Firmware release
status
TYPFWA

Fig. 3-10: Firmware configuration rating plate

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

DDS02.1/03.1 drive controllers

3-9

DDS02.1/03.1

3.5

Plugin module
Only a few of the plugin modules are introduced below. The precise
functions offered by a specific firmware verison are outlined in the respective function description.
SERCOS interface

Type: DSS01.1, DSS01.3
The plugin module " SERCOS interface DSS " makes it possible to operate
the digital drive with SERCOS interface compatible controls via a fiber
optic cable. It also offers inputs for evaluating reference switches, travel
range limit switches and sensor inputs.

ANALOG interface with
incremental encoder emulator

Type: DAE01.1

ANALOG interface with
absolute encoder emulator

Type: DAA01.1

Single axis positioning module

The plugin module " ANALOG interface with incremental encoder emulator " makes it possible to operate digital intelligent AC servo drives with
conventional controls via an analog interface. It also contains control inputs and signal outputs for communicating with a connected control and
generates incremental encoder signals for use as actual position values.

The plugin module " ANALOG interface with absolute encoder emulator "
makes it possible to operate digital intelligent AC servo drives with conventional controls via an analog interface. It also contains control inputs
and signal outputs for communicating with a connected control and generates actual position values which meet the SSI standard (synchronous
serial interface).
Type: DLC01.1, DLC02.1
The plugin module " single axis positioning module " expands the drive
controller to create a standalone single axis positioning unit. This control
can be programmed with up to 3000 program blocks. Each program block
describes one motion sequence or a specific state of the inputs to be
monitored or the outputs to be set. The DLC02.1 is functionally compatible with the DLC01.1. The DLC02.1, however, also has an additional interface to connect an INTERBUS-S module DBS02.2 .

Interbus S Slave interface

Type: DBS02.1
The interbus S slave interface DBS02.1 makes it possible to directly load
speed values as per the DRIVECOM standard profile 21.

Interbus-S-Slave Interface

Type: DBS02.2
The interbus S slave interface DBS02.2 means that a DLC02.1 single
positioning module can be connected which directly loads target positions
as per DRIVECOM standard profile 22 and can handle the I/O level of the
DLC.

Command card

Type: CLC-...
The CLC-... command card supports the central control of the drive units
for the implementation of the " electronic shaft“.

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

DDS02.1/03.1 drive controllers

3-10

DDS02.1/03.1

ARCNET coupler card

Type. DAK01.1
The DAK01.1 plugin module is a stackable card for the CLC-D02... command card and creates the interface to an ARCNET bus system.

Input/output interface

Type: DEA04.1, DEA05.1, DEA06.1
These plugin modules each have 15 inputs and 16 outputs via which the
drive can exchange binary signals with a PLC. They are differentiated in
terms of the address set.

Incremental position interface

Type: DEF01.1, DEF02.1
The plugin module " incremental position interface " supports the transmission of square wave signals for evaluating an external scale directly
mounted to the moving machine component in the drive controller. They
are differentiated in terms of the address set.

High resolution position
interface

Type: DLF01.1

Summing input interface

Type: DSE01.1

The plugin module " high resolution position interface " supports the
transmission of sinusoidal signals for evaluating an external scale directly
mounted to the moving machine component in the drive controller.

The plugin module " summing input interface " makes two summing inputs
available in addition to the differential input for a configuration with analogue interface. It is possible, via these summing inputs, to apply additional
command values for the differential input at the analog interface.
Gearwheel encoder interface

Type: DZF01.1, DZF02.1
The plugin module „gearwheel interface“ supports the evaluation of the
high-resolution main spindle position encoder.

Note:

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

The technical data and the terminal diagrams of the plugin
modules can be found in the document " DIAX02 plugin module for digital intelligent drive controllers " .

DDS02.1/03.1 drive controllers

3-11

DDS02.1/03.1

3.6

Configuration rating plate
The type designations are on the configuration rating plate:
• the configured drive controller,
• the basic unit,
• the software module in slot U5
• and the plugin modules in slots U1 to U4.
These type designations can be used to determine which components
ought to be in which slots.
In the event of a breakdown, the information on this plate can be used to
quickly and efficiently obtain the correct replacement parts.

Note:

The configuration rating plate supplies information about which
modules of the drive controllers are in place. Please check,
prior to commissioning the controller, that the correct modules
are in place.

Note:

When mounting the drive controller, the face plate is removed
from the controller with the rating plate. Please make sure that
the face plate is remounted to the drive controller from which it
was removed.

SYSTEMCONFIGURATION
Configured
drive controller
type
Basic unit
type

DDS 02.1-W050-DS04-03-FW
DDS 02.1-W050-D
U
1 DSS 01.3-FW
U
2 DLF 01.1

Slot
designation

Plugin module
type

U COVER
3
U COVER
4

Configured drive
controller part no.

Software
module

U
5 DSM 02.1-FW
269421

K42/96

COVER = no plugin module in slot

Shipping date
week/year
TSDDS2.WMF

Fig. 3-11: An example of a configuration rating plate

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

DDS02.1/03.1 drive controllers

3-12

DDS02.1/03.1

3.7

Summary of components fitted in a configuration
Use this summary to identify which plugin module ought to be in a specific
drive controller configuration.
Compare the configuration in the summary with the type of the configured
drive controller.
If the suffix of the type designation agrees with a configuration in the
summary, then the summary should list what is fitted into slots 1 through
4 of the basic unit.
This summary is no selection list for available configurations.

Configuration

Basic unit

Slot U1

Slot U2

Slot U3

Slot U4

Slot U5

DA01-01-FW

DDS0*.1-****-D

DAE01.1

COVER

COVER

COVER

DSM02.1-FW

DA02-01-FW

DDS0*.1-****-D

DAA01.1

COVER

COVER

COVER

DSM02.1-FW

DA03-01-FW

DDS0*.1-****-D

DAE01.1

DEA04.2

COVER

COVER

DSM02.1-FW

DA06-01-FW

DDS0*.1-****-D

DAE01.1

DLF01.1

COVER

COVER

DSM02.1-FW

DA07-02-FW

DDS0*.1-****-D

DAE01.1

DZF02.1

COVER

COVER

DSM02.1-FW

DA10-01-FW

DDS0*.1-****-D

DAE01.1

DEF01.1

COVER

COVER

DSM02.1-FW

DA11-01-FW

DDS0*.1-****-D

DAE01.1

DSE01.1

COVER

COVER

DSM02.1-FW

DA12-01-FW

DDS0*.1-****-D

DAA01.1

DSE01.1

COVER

COVER

DSM02.1-FW

DA14-01-FW

DDS0*.1-****-D

DAE01.1

DRF01.1

COVER

COVER

DSM02.1-FW

DC01-01-FW

DDS0*.1-****-D

DBS02.1-FW

COVER

COVER

COVER

DSM02.1-FW

DC02-01-FW

DDS0*.1-****-D

DBS02.1-FW

DEA04.1

COVER

COVER

DSM02.1-FW

DC03-01-FW

DDS0*.1-****-D

DBS02.1-FW

DEA04.1

DEA05.1

COVER

DSM02.1-FW

DC04-01-FW

DDS0*.1-****-D

DBS02.1-FW

DZF01.1

COVER

COVER

DSM02.1-FW

DL01-01-FW

DDS0*.1-****-D

DLC01.1-FW

DEA04.1

COVER

COVER

DSM02.1-FW

DL02-01-FW

DDS0*.1-****-D

DLC01.1-FW

DEA04.1

DEA05.1

COVER

DSM02.1-FW

DL03-01-FW

DDS0*.1-****-D

DLC01.1-FW

DEA04.1

DEA05.1

DEA06.1

DSM02.1-FW

DL04-01-FW

DDS0*.1-****-D

DLC01.1-FW

DEA04.1

DEF01.1

COVER

DSM02.1-FW

DL05-01-FW

DDS0*.1-****-D

DLC01.1-FW

DEA04.1

DEA05.1

DEF01.1

DSM02.1-FW

DL08-01-FW

DDS0*.1-****-D

DLC01.1-FW

DEA04.1

DFF01.1

COVER

DSM02.1-FW

DL09-01-FW

DDS0*.1-****-D

DLC01.1-FW

DEA04.1

DEA05.1

DFF01.1

DSM02.1-FW

DL10-01-FW

DDS0*.1-****-D

DLC01.1-FW

DEA04.1

DEF01.1

DEF02.1

DSM02.1-FW

DL11-01-FW

DDS0*.1-****-D

DLC01.1-FW

DEA04.1

DZF01.1

COVER

DSM02.1-FW

DL12-01-FW

DDS0*.1-****-D

DLC01.1-FW

DEA04.1

DEA05.1

DZF01.1

DSM02.1-FW

DL13-01-FW

DDS0*.1-****-D

DLC01.1-FW

DEA04.1

DEF02.1

DLF01.1

DSM02.1-FW

DL14-01-FW

DDS0*.1-****-D

DLC01.1-FW

DEA04.1

DLF01.1

COVER

DSM02.1-FW

DL20-01-FW

DDS0*.1-****-D

DLC02.1-FW

DBS02.2-FW

COVER

COVER

DSM02.1-FW

DL21-01-FW

DDS0*.1-****-D

DLC02.1-FW

COVER

DBS02.2-FW

COVER

DSM02.1-FW

DL22-01-FW

DDS0*.1-****-D

DLC02.1-FW

DBS02.2-FW

DEA04.1

COVER

DSM02.1-FW

DL23-01-FW

DDS0*.1-****-D

DLC02.1-FW

DEA04.1

DBS02.2-FW

COVER

DSM02.1-FW

DL24-01-FW

DDS0*.1-****-D

DLC02.1-FW

DBS02.2-FW

DEA04.1

DEA05.1

DSM02.1-FW

DL25-01-FW

DDS0*.1-****-D

DLC02.1-FW

DEA04.1

DBS02.2-FW

DEA05.1

DSM02.1-FW

DL26-01-FW

DDS0*.1-****-D

DLC02.1-FW

DBS02.2-FW

DEA04.1

DEF01.1

DSM02.1-FW

DL27-01-FW

DDS0*.1-****-D

DLC02.1-FW

DEA04.1

DBS02.2-FW

DEF01.1

DSM02.1-FW

DL28-01-FW

DDS0*.1-****-D

DLC02.1-FW

DBS02.2-FW

DFF01.1

COVER

DSM02.1-FW

DL29-01-FW

DDS0*.1-****-D

DLC02.1-FW

DFF01.1

DBS02.2-FW

COVER

DSM02.1-FW

DL30-01-FW

DDS0*.1-****-D

DLC02.1-FW

DBS02.2-FW

DEF01.1

COVER

DSM02.1-FW

DL31-01-FW

DDS0*.1-****-D

DLC02.1-FW

DEF01.1

DBS02.2-FW

COVER

DSM02.1-FW

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

DDS02.1/03.1 drive controllers

3-13

DDS02.1/03.1

Configuration

Basic unit

Slot U1

Slot U2

Slot U3

Slot U4

Slot U5

DL40-01-FW

DDS0*.1-****-D

DLC01.1-FW

DPF02.1

COVER

COVER

DSM02.1-FW

DL41-01-FW

DDS0*.1-****-D

DLC01.1-FW

DPF02.1

DEF01.1

COVER

DSM02.1-FW

DL42-01-FW

DDS0*.1-****-D

DLC01.1-FW

DPF02.1

DFF01.1

COVER

DSM02.1-FW

DL43-01-FW

DDS0*.1-****-D

DLC01.1-FW

DPF02.1

DPF03.1

COVER

DSM02.1-FW

DL45-01-FW

DDS0*.1-****-D

DLC01.1-FW

DPF02.1

DEA05.1

COVER

DSM02.1-FW

DS01-02-FW

DDS0*.1-****-D

DSS01.3-FW

COVER

COVER

COVER

DSM02.1-FW

DS03-02-FW

DDS0*.1-****-D

DSS01.3-FW

DEF01.1

COVER

COVER

DSM02.1-FW

DS04-03-FW

DDS0*.1-****-D

DSS01.3-FW

DLF01.1

COVER

COVER

DSM02.1-FW

DS05-01-FW

DDS0*.1-****-D

DSS01.1-FW

DEF01.1

DEF02.1

COVER

DSM02.1-FW

DS06-02-FW

DDS0*.1-****-D

DSS01.1-FW

DLF01.1

DFF01.1

CLC-D02.1A-FW

DSM02.1-FW

DS08-01-FW

DDS0*.1-****-D

DSS01.1-FW

DLF01.1

DFF01.1

COVER

DSM02.1-FW

DS09-01-FW

DDS0*.1-****-D

DSS01.3-FW

DFF01.1

COVER

COVER

DSM02.1-FW

DS13-01-FW

DDS0*.1-****-D

DSS01.1-FW

DLF01.1

COVER

COVER

DSM02.1-FW

DS22-02-FW

DDS0*.1-****-D

DSS01.3-FW

DLF01.1

DEA04.2

COVER

DSM02.1-FW

DS24-03-FW

DDS0*.1-****-D

DSS01.3-FW

CLC-D02.1A-FW

DEA04.2

COVER

DSM02.1-FW

DS25-01-FW

DDS0*.1-****-D

DSS01.1-FW

DLF01.1

DSS02.1

COVER

DSM02.1-FW

DS37-01-FW

DDS0*.1-****-D

DSS01.3-FW

DZF02.1

COVER

COVER

DSM02.1-FW

DS40-02-FW

DDS0*.1-****-D

DSS01.3-FW

DRF01.1

COVER

COVER

DSM02.1-FW

DS41-00-FW

DDS0*.1-****-D

DSS01.3-FW

CLC-D02.1A-FW

COVER

COVER

DSM02.1-FW

DS45-00-FW

DDS0*.1-****-D

DSS01.3-FW

CLC-D02.1A-FW

DEA04.2

DEA05.2

DSM02.1-FW

DS46-00-FW

DDS0*.1-****-D

DSS01.3-FW

CLC-D02.2A-FW

DBS03.1-FW

COVER

DSM02.1-FW

DS46-01-FW

DDS0*.1-****-D

DSS01.3-FW

CLC-D02.2A-FW

COVER

DBS03.1-FW

DSM02.1-FW

DS47-00-FW

DDS0*.1-****-D

DSS01.3-FW

CLC-D02.2A-FW

DBS03.1-FW

DLF01.1

DSM02.1-FW

DS47-01-FW

DDS0*.1-****-D

DSS01.3-FW

CLC-D02.2A-FW

DLF01.1

DBS03.1-FW

DSM02.1-FW

DS48-00-FW

DDS0*.1-****-D

DSS01.1-FW

DLF01.1

DEF02.1

COVER

DSM02.1-FW

DS50-00-FW

DDS0*.1-****-D

DSS01.3-FW

CLC-D02.2A-FW

DEA04.2

COVER

DSM02.1-FW

DS51-00-FW

DDS0*.1-****-D

DSS01.3-FW

CLC-D02.2A-FW

DEA04.2

DLF01.1

DSM02.1-FW

DS51-01-FW

DDS0*.1-****-D

DSS01.3-FW

CLC-D02.1A-FW

DEA04.2

DLF01.1

DSM02.1-FW

DS53-00-FW

DDS0*.1-****-D

DSS01.3-FW

CLC-D02.1A-FW

DEA04.2

DEF02.1

DSM02.1-FW

DS54-00-FW

DDS0*.1-****-D

DSS01.3-FW

DEA04.2

DEA05.2

COVER

DSM02.1-FW

DS55-00-FW

DDS0*.1-****-D

DSS01.3-FW

DEF01.1

DEA04.2

COVER

DSM02.1-FW

DS56-00-FW

DDS0*.1-****-D

DSS01.3-FW

DEA04.2

COVER

COVER

DSM02.1-FW

DS57-00-FW

DDS0*.1-****-D

DSS01.3-FW

CLC-D02.2A-FW

DBS03.1-FW

DEF01.1

DSM02.1-FW

DS57-01-FW

DDS0*.1-****-D

DSS01.3-FW

CLC-D02.2A-FW

DEF01.1

DBS03.1-FW

DSM02.1-FW

DS58-00-FW

DDS0*.1-****-D

DSS01.3-FW

CLC-D02.2A-FW

DPF05.1-FW

COVER

DSM02.1-FW

DS58-50-FW

DDS0*.1-****-D

DSS01.3-FW

CLC-D02.2A-FW

COVER

DPF05.1-FW

DSM02.1-FW

DS59-00-FW

DDS0*.1-****-D

DSS01.3-FW

CLC-D02.2A-FW

DPF05.1-FW

DLF01.1

DSM02.1-FW

DS59-50-FW

DDS0*.1-****-D

DSS01.3-FW

CLC-D02.2A-FW

DLF01.1

DPF05.1-FW

DSM02.1-FW

DS60-00-FW

DDS0*.1-****-D

DSS01.3-FW

CLC-D02.2A-FW

DPF05.1-FW

DEF01.1

DSM02.1-FW

DS60-50-FW

DDS0*.1-****-D

DSS01.3-FW

CLC-D02.2A-FW

DEF01.1

DPF05.1-FW

DSM02.1-FW

DS61-00-FW

DDS0*.1-****-D

DSS01.3-FW

DEA04.2

DEA05.2

DLF01.1

DSM02.1-FW

RA01-02-FW

DDS0*.1-****-R

DAE01.1

COVER

COVER

COVER

DSM02.1-FW

RA02-02-FW

DDS0*.1-****-R

DAA01.1

COVER

COVER

COVER

DSM02.1-FW

RA11-01-FW

DDS0*.1-****-R

DAE01.1

DSE01.1

COVER

COVER

DSM02.1-FW

RA12-01-FW

DDS0*.1-****-R

DAA01.1

DSE01.1

COVER

COVER

DSM02.1-FW

RC01-01-FW

DDS0*.1-****-R

DBS02.1-FW

COVER

COVER

COVER

DSM02.1-FW

RC02-01-FW

DDS0*.1-****-R

DBS02.1-FW

DEA04.1

COVER

COVER

DSM02.1-FW

RC03-01-FW

DDS0*.1-****-R

DBS02.1-FW

DEA04.1

DEA05.1

COVER

DSM02.1-FW

RL01-01-FW

DDS0*.1-****-R

DLC01.1-FW

DEA04.1

COVER

COVER

DSM02.1-FW

RL02-01-FW

DDS0*.1-****-R

DLC01.1-FW

DEA04.1

DEA05.1

COVER

DSM02.1-FW

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

DDS02.1/03.1 drive controllers

3-14

DDS02.1/03.1

Configuration

Basic unit

Slot U1

Slot U2

Slot U3

RL03-01-FW

DDS0*.1-****-R

DLC01.1-FW

DEA04.1

DEA05.1

RL04-01-FW

DDS0*.1-****-R

DLC01.1-FW

DEA04.1

RL05-01-FW

DDS0*.1-****-R

DLC01.1-FW

DEA04.1

RL08-01-FW

DDS0*.1-****-R

DLC01.1-FW

RL09-01-FW

DDS0*.1-****-R

RL10-01-FW
RL20-01-FW

Slot U4

Slot U5

DEA06.1

DSM02.1-FW

DEF01.1

COVER

DSM02.1-FW

DEA05.1

DEF01.1

DSM02.1-FW

DEA04.1

DFF01.1

COVER

DSM02.1-FW

DLC01.1-FW

DEA04.1

DEA05.1

DFF01.1

DSM02.1-FW

DDS0*.1-****-R

DLC01.1-FW

DEA04.1

DEF01.1

DEF02.1

DSM02.1-FW

DDS0*.1-****-R

DLC02.1-FW

DBS02.2-FW

COVER

COVER

DSM02.1-FW

RL21-01-FW

DDS0*.1-****-R

DLC02.1-FW

COVER

DBS02.2-FW

COVER

DSM02.1-FW

RL22-01-FW

DDS0*.1-****-R

DLC02.1-FW

DBS02.2-FW

DEA04.1

COVER

DSM02.1-FW

RL23-01-FW

DDS0*.1-****-R

DLC02.1-FW

DEA04.1

DBS02.2-FW

COVER

DSM02.1-FW

RL24-01-FW

DDS0*.1-****-R

DLC02.1-FW

DBS02.2-FW

DEA04.1

DEA05.1

DSM02.1-FW

RL25-01-FW

DDS0*.1-****-R

DLC02.1-FW

DEA04.1

DBS02.2-FW

DEA05.1

DSM02.1-FW

RL26-01-FW

DDS0*.1-****-R

DLC02.1-FW

DBS02.2-FW

DEA04.1

DEF01.1

DSM02.1-FW

RL27-01-FW

DDS0*.1-****-R

DLC02.1-FW

DEA04.1

DBS02.2-FW

DEF01.1

DSM02.1-FW

RL28-01-FW

DDS0*.1-****-R

DLC02.1-FW

DBS02.2-FW

DFF01.1

COVER

DSM02.1-FW

RL29-01-FW

DDS0*.1-****-R

DLC02.1-FW

DFF01.1

DBS02.2-FW

COVER

DSM02.1-FW

RL30-01-FW

DDS0*.1-****-R

DLC02.1-FW

DBS02.2-FW

DEF01.1

COVER

DSM02.1-FW

RL31-01-FW

DDS0*.1-****-R

DLC02.1-FW

DEF01.1

DBS02.2-FW

COVER

DSM02.1-FW

RS01-03-FW

DDS0*.1-****-R

DSS01.3-FW

COVER

COVER

COVER

DSM02.1-FW

RS03-03-FW

DDS0*.1-****-R

DSS01.3-FW

DEF01.1

COVER

COVER

DSM02.1-FW

RS04-03-FW

DDS0*.1-****-R

DSS01.3-FW

DLF01.1

COVER

COVER

DSM02.1-FW

RS16-02-FW

DDS0*.1-****-R

DSS01.3-FW

DZF02.1

COVER

COVER

DSM02.1-FW

RS18-02-FW

DDS0*.1-****-R

DSS01.3-FW

DEA04.2

COVER

COVER

DSM02.1-FW

Fig. 3-12: Summary of components of the basic units fitted in different configurations

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

DDS02.1/03.1 drive controllers

3-15

DDS02.1/03.1

4

Technical data

4.1

Power section
DC bus voltage

Designation

Value
300 +/- 15%

DC bus voltage
Fig. 4-1: DC bus voltage

Allocation of peak and
continuous currents

Unit
V

An " overload factor " can be found in the motor/controller selection list.
Using this overload factor it is possible to set the continuous current of the
controller at the time of commissioning in terms of the motor. The controller peak current is set as dependent upon the continuous controller current.
In the second column, the possible continuous current is listed for the
maximum peak current and in the third column, the possible peak current
is given for the maximum continuous current in the following list.

Drive controller

Maximum peak current / continuous
current

Peak current / maximum continuous
current

DDS02.1-W015-...

15A / 15A

15A / 15A

DDS02.1-W025-...

25A / 25A

25A / 25A

DDS03.1-W030-...

30A / 10A

15A / 15A

DDS03.1-W050-...

50A / 20A

50A / 20A

DDS02.1-W050-...

50A / 40A

50A / 40A

DDS02.1-A050-...

50A / 50A

50A / 50 A

DDS02.1-F050-...

50A / 50A

50A / 50A

DDS02.1-W100-...

100A / 40A

60A / 60A

DDS02.1-A100-...

100A / 80A

90A / 90A

DDS02.1-F100-...

100A / 100A

100A / 100A

DDS02.1-W150-...

150A / 65A

80A / 80A

DDS02.1-A150-...

150A / 105A

150A / 105A

DDS02.1-F150-...

150A / 105A

150A / 105A

DDS02.1-W200-...

200A / 65A

90A / 90A

DDS02.1-A200-...

200A / 85A

160A / 105A

DDS02.1-F200-...
200A / 105A
Fig. 4-2: Allocating peak and continuous currents

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

200A / 105A

Technical data 4-1

DDS02.1/03.1

4.2

Current consumed during signal processing

Current consumed during
signal processing

The supply unit makes available the DC +24V - and DC +/- 15V - voltages
for all connected drive controllers. The sum of the current consumed by
all the controllers connected to the supply unit may not exceed the permissible current output of the supply unit.
Generally applicable for the current consumption of the drive controller is
DC +/-15V ea. 200 mA , for DC +24V 1100 mA.
For detailed calculations, the current consumption for one drive unit can
be determined as follows:
Current consumption of the basic unit
+ current consumption of the plugin module in the basic unit
+ current consumption of the motor feedback with MDD and MKD motors
= current consumption for one drive unit

Current consumption of the
basic unit

Controller types

Current consumption DC
+15V in mA

Current consumption DC
-15V in mA

Current consumption DC
+24V in mA

DDS02.1-...

150

150

500

150

500

DDS03.1-...
150
Fig. 4-3: Current consumption of the basic unit

Current consumption of the
motor feedback

Use the type code of the motor to locate the designation of the motor
feedback.

Motor feedback

Current consumption DC
+15V in mA

Current consumption DC
-15V in mA

Current consumption DC
+24V in mA

G

25

5

0

K

25

5

0

L

0

0

40

M

0

0

60

S

0

0

40

0

0

T
20
Fig. 4-4: Motor feedback current consumption

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Technical data 4-2

DDS02.1/03.1

Current consumption of the
plugin modules

Plugin module
type

Current consumption DC
+15V in mA

Current consumption DC
-15V in mA

Current consumption DC
+24V in mA

CLC-D02.1A-FW

0

0

200

CLC-D02.2A-FW

0

0

200

DAA01.1

30

30

70

DAE01.1

30

30

70

DAK01.1A

0

0

70

DBS02.1-FW

0

0

130

DBS02.2-FW

0

0

130

DBS03.1-FW

0

0

130

DEA04.1

0

0

40

DEA04.2

0

0

40

DEA05.1

0

0

40

DEA05.2

0

0

40

DEA06.1

0

0

40

DEF01.1

0

0

150

DEF02.1

0

0

150

DFF01.1

45

45

45

DLC01.1

0

0

80

DLC02.1

0

0

80

DLC02.1-FW

0

0

80

DLF01.1

40

40

130

DPF05.1-FW

0

0

100

DRF01.1

50

50

15

DSE01.1

20

10

0

DSS01.1

0

0

110

DSS01.3-FW

0

0

110

DSS02.1

0

0

110

DZF01.1

30

40

150

DZF02.1
30
40
Fig. 4-5: Current consumption of the plugin module

150

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Technical data 4-3

DDS02.1/03.1

4.3

Ambient and environmental conditions

Designation

Value
+0...+45

Permissible ambient temperature with rated data
Max. Permissible ambient temperature with derated data

Unit
ºC

+55

ºC

-30...+85

ºC

1000

m

Max. Permissible relative air humidity

95

%

Max. Permissible absolute air humidity

25

g/m

Storage and transport temperature
Max. Installation elevation with rated data

Protection category

IP20, per EN 60529 = DIN VDE
0470-1-1992 (IEC 529-1989)
Fig. 4-6: Ambient and environmental conditions

Deviating ambient conditions

3

Selection data are listed for each motor/controller combination.
These data apply within the indicated ambient temperature and installation elevations.
If conditions differ, then the continuous torque at standstill MdN and shortterm torque MKB drop as illustrated. If both occur simultaneously, then
both load factors must be multiplied.

Reduction factor of the torque indicated in the selection lists

1

0.8

0.6

40

45

50

Ambient temperature in °C

Depends on
installation elev.

1

Reduction factor fH

Reduction factor fT

Depends on ambient
temperature

55

0.8

0.6

0

1000 2000 3000 4000 5000

Installation elev. in m above sea level
umgetemp.fh5

Fig. 4-7: Load capacitiy as dependent on ambient temperature and installation
elevation

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Technical data 4-4

DDS02.1/03.1

4.4

Drive controller energy loss
Determining energy loss in the controller by adding the maximum energy
loss to the controller type does not account for the actual continous load
of the controller.
Over an average period of time, the maximum amount of the continuous
current at standstill IdN of the motor flows through the controller (see motor
documentation).
The actually resulting energy loss depends on the continuous current at
standstill IdN of the connected motor. The continous current at standstill IdN
is listed in the motor documentation.
Controller:

DDS 2.1 - W050 - …

Motor:

MDD 093A-N-020-…

Standstill current IdN of the motor:

Example: determining energy
loss

9.5A

Energy loss as determined
in Fig. 4-8:

approx.. 80 W

Energy loss in the control
cabinet

Power dissipation Pv in W

Energy loss in the DDS02.1-W...

600

max. energy loss
560

Drive controller
DDS 2.1-W200-...

440

DDS 2.1-W150-...

500

400

380

DDS 2.1-W100-...

300
DDS 2.1-W050-...

260
200
170
100

110

10
DGVERLIN

DDS 2.1-W025-...
DDS 2.1-W015-...

20

30

40

50

60

70

80

90

Cont. current at standstill of motor IdN in A

Fig. 4-8: Determining the energy lost in the control cabinet

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Technical data 4-5

DDS02.1/03.1

Energy loss in the control
cabinet

Power dissip. Pv in W

Energy loss in the DDS02.1-A...

120

100

Drive controllers
DDS 2.1-A200-...
DDS 2.1-A150-...

max. power dissip.
120

97

DDS 2.1-A100-...

80

60
54

DDS 2.1-A050-...

40

20

20

40

60

80

100

120

PVDDS2A

Motor cont. curr. at standstill IdN in A

Energy loss outside the control
cabinet

Power dissip. Pv in W

Fig. 4-9: Determining the energy lost in the control cabinet

500

max. power dissip.
477

400

380

Drive controllers
DDS 2.1-A200-...
DDS 2.1-A150-...

DDS 2.1-A100-...

300

200

215

DDS 2.1-A050-...

100

PEXDDS2A

20

40

60

80

100

120

Motor cont. curr. at standstill IdN in A

Fig. 4-10: Determining the energy lost via the heatsink and conducted outside the
control cabinet

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Technical data 4-6

DDS02.1/03.1

Energy loss in the control
cabinet

Power dissip. Pv in W

Energy loss in the DDS02.1-F...

120

100

max. power dissip.
120

97

Drive controllers
DDS 2.1-F200-...
DDS 2.1-F150-...

DDS 2.1-F100-...

80

60
54

DDS 2.1-F050-...

40

20

20

40

60

PVDDS2F

80

100

120

Motor cont. curr. at standstill IdN in A

Fig. 4-11:Determining energy lost in the control cabinet

Power dissip. Pv in W

Energy loss via the coolant
500

400

max. power loss
477

Drive controllers
DDS 2.1-F200-...
DDS 2.1-F150-...
DDS 2.1-F100-...

380

300

200

215

DDS 2.1-F050-...

100

PEXDDS2F

20

40

60

80

100

120

Motor cont. curr. at standstill IdN in A

Fig. 4-12: Determining energy lost via the coolant

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Technical data 4-7

DDS02.1/03.1

Energy loss in the DDS03.1-W...
Energy loss in the control
cabinet
Power dissip. Pv in W

150

max. power dissip.
140

drive contr. type
DDS 3.1-W050-...

110

DDS 3.1-W030-...

100

50

DGViDDS3

5

10

15

20

Motor cont. current at standstill IdN in A

Fig. 4-13: Determining energy lost in the control cabinet

4.5

Weight
Drive controller type

Weight in kg

DDS02.1-W...-. (heat technology)

approx. 7.5

DDS02.1-A...-. (cold technology)

approx. 11

DDS02.1-F...-. (liquid cooling)

approx. 11

DDS03.1-W...-. (heat technology)
Fig. 4-14: Drive controller weight

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

approx. 5.5

Technical data 4-8

DDS02.1/03.1

5

Planning the construction of the control cabinet
Mounting conditions

The drive controller and its supply unit are designed for mounting into a
control cabinet or a closed housing and meet the demands of protection
category IP 10, as per DIN 40 050.
The unit is protected against penetration by a solid extrinsic object with a
diameter exceeding 50 mm.
The unit is not protected against
• penetration by water
• intentional accessing by a hand, for example, but it will keep larger
body surfaces out.

Arranging the controller

Position the drive with high output and excessive current levels as close
to the supply unit as possible.

Supply unit

Controller with
high output

Controller with
low output

Mains conn.

ATTENTION!
NEVER REMOVE OR INSTALL THIS
PLUGS WHILE VOLTAGE IS APPLIED.
BLACK CABLE ON THE BOTTOM!
Verbindung nie unter Spannung
lösen bzw. stecken.
Schwarze Leitung immer unten!

ATTENTION!
NEVER REMOVE OR INSTALL THIS
PLUGS WHILE VOLTAGE IS APPLIED.
BLACK CABLE ON THE BOTTOM!
Verbindung nie unter Spannung
lösen bzw. stecken.
Schwarze Leitung immer unten!

X5b
ATTENTION!
NEVER REMOVE OR INSTALL THIS
PLUGS WHILE VOLTAGE IS APPLIED.
BLACK CABLE ON THE BOTTOM!
Verbindung nie unter Spannung
lösen bzw. stecken.
Schwarze Leitung immer unten!

ATTENTION!
NEVER REMOVE OR INSTALL THIS
PLUGS WHILE VOLTAGE IS APPLIED.
BLACK CABLE ON THE BOTTOM!
Verbindung nie unter Spannung
lösen bzw. stecken.
Schwarze Leitung immer unten!

GADDS3

Fig. 5-1: Recommended position of the unit inside the control cabinet

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Planning the construction of the control cabinet 5-1

DDS02.1/03.1

Clearance dimensions DDS02.1

110 ±0,5

110 ±0,5 110 ±0,5

TVD
KDV3
KDV4
TVR3

DDS 2

155 ±0,5

DDS 2

TVD
KDV3
KDV4
TVR3

110 ±0,5

TVM
2.1
2.4

DDS 2

TVD
KDV3
KDV4
TVR3

DDS 2

110 ±0,5

KDV2.2
KDV2.3

DDS 2

110 ±0,5 110 ±0,5

KVR 1

DDS 2

DDS 2

TDA
KDA3.2

110 ±0,5

DDS 2

155 ±0,5

200 ±0,5

TDA
KDA3.2

TVD
KDV3
KDV4
TVR3

110 ±0,5 110 ±0,5

DDS 2

KVR 1

60
GATeil

Fig. 5-2: Clearance dimensions of the DDS02.1 within the control cabinet

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Planning the construction of the control cabinet 5-2

DDS02.1/03.1

Clearance dimensions for
DDS03.1

110 ±0,5

TVD
KDV 3
KDV 4
TVR 3

137 ±0,5

TDA
KDA 3.2

92 ±0,5

DDS 3

DDS 3

200 ±0,5

TDA
KDA3.2

92 ±0,5 74 ±0,5

155 ±0,5

DDS 3

DDS 3 DDS 3

TVD
KDV 3
KDV 4
TVR 3

110 ±0,5 92 ±0,5

KVR 1

DDS 3

TVD
KDV 3
KDV 4
TVR 3

92 ±0,5 110 ±0,5

DDS 3

DDS 3

92 ±0,5

92 ±0,5

KDV
2.2
2.3

TVD
KDV3
KDV4
TVR3

TVM
2.1
2.4

DDS 3

KVR 1

92 ±0,5

DDS 2

DDS 3

60
GATEDDS3

Fig. 5-3: Clearance dimensions for the DDS03.1 within the control cabinet

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Planning the construction of the control cabinet 5-3

DDS02.1/03.1

5.1

Mounting the DDS02.1-W... drive controller
7
8

air outlet

(18)

min. 80 mm

13

1

X6

6

S1

A1

A2

H1

A3

U5

L-

373

X5

390

355

Guard

L+

X1
U1 U2

U3

U4
X2

X3
1

9

1

min. 80 mm

17

15

11
X4
8

air
inlet

=

105

22.5

min.
40 mm
free

=

7

60

Machine screw M6 (DIN 912)
(Allen screw)

325

Mounting panel or
control cabinet back wall
X8

Allen screw driver 906q / SW 5x400-46185
Ident. no. 221 672 (avail. upon request)

A1

S1
A2
A3
L-

Connection

Tightening
torque

A1 ; A2 ; A3 = M6

MA = 5 Nm

L- ; L+ ; PE = M5

L+

MA = 3 Nm

MA

X1

1

Weight: approx. 7.5

11

MBDDS2W

Fig. 5-4: Dimensional sheet - DDS02.1-W...

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Planning the construction of the control cabinet 5-4

DDS02.1/03.1

5.2

Mounting the DDS02.1-A... drive controller

intern

extern

Drive controller mounted into
the control cabinet

Air baffle

Power dissip.

DDS2.•-A...
heatsink

ext.
blower

completely sealed
housing or cabinet

VerDDS2A

Fig. 5-5: The DDS02.1-A... drive controller mounted in the control cabinet
Power dissipation

The DS02.1-A... drive controller has the advantage that most of the energy lost by the unit is directly conducted outside thus not accumulating
within the control cabinet. These units can therefore be mounted into
small control cabinets or housing without requiring extensive heat conductance or expensive heat-exchanging units.

Blower unit

The electrical section of the blower is protected within the control cabinet
(see Fig. 5-5). The heatsink of the power section and the blower impeller
are outside the control cabinet or housing.

Mounting panel

Using a mounting panel, the units are mounted into the therefore provided
space on the backwall of the cabinet in such a way that the heatsink with
casing sticks out of the cabinet. The opening within the cabinet is sealed
with a seal ring at the mounting flange of the unit after mounting (see Fig.
5-7). Mounting and exchange of the drive controller and external blower
can be performed on the inside of the control cabinet.

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Planning the construction of the control cabinet 5-5

23
10

min. 80 mm free

355

min. 80 mm free

345
14

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Guard

min.
40 mm
free

325

X13

MA = 5 Nm

Tightening
torque

MA = 3 Nm

A1 ; A2 ; A3 = M6

Connection

X5

U1 U2

L+

L-

A3

A2

A1

Weight: approx. 11 kg

heatsink

160

L- ; L+ ; PE = M5

H1

X6

9

15

U4

MA

U3

U5

105

1

8
373

390
MBDDS2A

X14a
X14b

11
X4
8

X3
1

X2

X1

S1

6

1

DDS02.1/03.1

Dimensional sheet

Fig. 5-6: Dimensional sheet of the DDS02.1-A... drive controller

Planning the construction of the control cabinet 5-6

Allen screw
with SW5

Note the conductive connection
between back wall of control
cabinet and mounting panel!

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

machine screw / 4x
M4x18Z4-1 DIN912 (1)

blower 109-0575-4832-XX (1)

(2) contact disc M4/4x

machine screw / 4x
M4x16 DIN912 (2)

machine screw / 2x
M4x14Z4 DIN912 (1)

space for additional KD modules

M8 thread

185

finger guard (1)

KD module mounting frame (2)

blower mounting frame (1)

Parts designated with (2) are in the kit M1-KD.

Parts designated with (1) are in the blower.

housing back wall
housing and cabinet design

space for further blowers

M4 thread

69

air baffle (1)

DDS02.1/03.1

Mounting plans - DDS02.1-A...

MZDDS2A

Fig. 5-7: Mounting the DDS02.1-A... drive controller

Planning the construction of the control cabinet 5-7

DDS02.1/03.1

Installation dimensions DDS02.1-A...

min. 400

185
min. 2

min. 80

air flow
direction

air guard

69

325

355

Mounting frame KD module

421

heatsink

min. 200

160 in KDS/KDV
w/o ext.blower

ext.blower

dismantl. direction
blow.motor

completely sealed
housing or cabinet

blower mounting frame

110

min. 80

min. 80

KDV

DDS 2.•-A...

DDS 2.•-A...

DDS 2.•-A...

DDS 2.•-A...

18

174

X15

X15
F6

105

X15
F6

F6

fan

EinDDS2A

Fig. 5-8: Installation dimensions

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Planning the construction of the control cabinet 5-8

DDS02.1/03.1

Spacing and clearance
dimensions -DDS02.1-A...

Control cabinet interior
110±0.5

4 x ø5

110±0.5

110±0.5

11

15

96±0,5
=
=

403±0.2

86+1
space
for further
units,
dimen. as
unit 1

50+1

351+1

373±0.2

space
for
DDS 2.• - A

115
9

133±0.2

18

6 x ø5

space for ext. blower

=
=
92±0.2
92

GADDS2A

Fig. 5-9: Spacing and clearance dimensions - DDS02.1-A ...

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Planning the construction of the control cabinet 5-9

DDS02.1/03.1

Mounting the DDS02.1-F... drive controller

(18)

min. 80 mm

325

105
13

min.
25 mm
free

7
8

5.3

1
6

X6

S1

A1

H1

A2

Back wall of
control cabinet

A3

U5

L-

Guard

L+

373

355

X5

390

Mounting

X1
U1 U2

U3

U4
X2
X3
1

11
X4
8

9

1

30
=
22.5

=
60

7
125

165

min.
40 mm
free

150

min. 80 mm

17

15

75

Machine screw M6 (DIN 912)
(Allen screw)

M5

50
75

11

Opening for
guard in
panel

Mounting panel or
control cabinet back

X8

A1

S1
A2
A3

Weight: approx. 11

LL+

X1

Connection

tightening
torque

A1 ; A2 ; A3 = M6

Allen screw driver
906q / SW 5x400-46185
Ident. no. 221 672
(avail. upon request)

MA = 5 Nm

L- ; L+ ; PE = M5

1

MA

MA = 3 Nm

11

DDS21FMA

Fig. 5-10: Dimensional sheet DDS02.1-F... drive controller

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Planning the construction of the control cabinet 5-10

DDS02.1/03.1

Dimensional sheet
of accessory kit SH-FL

82

159

136

74

70

Cover

2x M5x12
5.5
7
MBzub

50
Fig. 5-11: Dimensional sheet - SH-FL accessory kit

Dimensional sheet
of accessory kit M2-F

approx. 50 (mounted)

coupling
SW 14
SW 19

MBsteck

Fig. 5-12: Dimensional sheet - M2-F accessory kit

Note:

Please note the mounting and installation guidelines outlined
in the document on " Liquid cooling Indramat drive components " (doc. no.: 209-0042-4131-00).

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Planning the construction of the control cabinet 5-11

DDS02.1/03.1

5.4

Mounting the DDS03.1-W...-. drive controller
70
13
7
8

(18)

min. 80 mm

325

air outlet

max.
1.5mm2
X6
U5

1
6

S1

guard

A3 A2 A1

max. 4mm2
H1

X5a
LL+

373

355

X5b
DDS 3.1-W030-D
-------ENA

K30/95

SN263508-04604

A00

390

mounting panel

X1

U1 U2
X2

max.
1.5mm2

X3
1

9

1

min. 80 mm

17

15

11
X4
8

7

air inlet

min.
40 mm
free

Connection

Tightening
torque

L- ; L+ ; PE = M5

Machine screw M6 (DIN 912)
(Allen screw)

MA = 3 Nm

MA

Weight: approx. 5.5
Mounting panel or
control cabinet back wall

A1

S1
A2
A3

X1

Allen screw driver
906q / SW 5x400-46185
Ident. no. 221 672
(avail. upon request)

1

11

MBDDS3

Fig. 5-13: Dimensional sheet - DDS03.1-W...-. drive controller

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Planning the construction of the control cabinet 5-12

DDS02.1/03.1

5.5

Interference suppression and EMC
The mounting and installation guidelines in the Project Planning Manual
on “EMC in drive and control systems” must be noted to maintain the legal EMC requirements.

5.6

Using heat-exchanger units in control cabinets
If heat-exchanging units are not installed and operated properly, then the
drive components inside the control cabinet could be damaged by moisture and condensation!

DANGER from condense water

DANGER from condensation

Avoiding moisture

Humid air penetrates the control cabinet and, when it cools, condenses
onto the drive components installed in there.
If the heat-exchanging unit is not located properly in the control cabinet,
then the water constantly condensing on it can drip into the installed
components or be sprayed into them by the cold air current.
Proper use of heat-exchanging units:
• Only use heat-exchanging units in well-sealed control cabinets so that
moisture cannot be brought in by any humid outside air.
• If the control cabinets are operated with opened doors, for startup,
servicing and so on, then make sure, once the doors are closed, that
the drive components are not at any time cooler than the air in the
control cabinet. Moisture can otherwise occur. For this reason, the
heat-exchanging unit must continue to operate even when the plant is
switched off so that the temperature of the control cabinet air and the
drive components installed remains at the same level.
• Set heat-exchanger units with permanent temperature adjustment to
40 °C. not lower!
• Set heat-exchanger units with temperature correction so that the inside temperature of the control cabinet is not lower than the outside air
temperature. Set the limit to 40 °C!

Avoiding dripping and spraying
water

Always situate heat-exchanging units so that any condensation cannot
drip into the installed drive components. Heat-exchangers on the control
cabinet roof require special control cabinet design!
Design the control cabinet in such a way that the unit fan cannot spray
condensation deposits onto the drive components after periods during
which the unit was not operational!

Summary

• Make sure that no condensation drips from the heat-exchanging unit
into the installed drive components!
• Make sure the temperature is set correctly on the heat-exchanger unit!

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Planning the construction of the control cabinet 5-13

DDS02.1/03.1

Heat-exchanger unit on the roof
of the control cabinet

correct

incorrect
cooling unit

cooling unit

cold

warm

warm

cold

air duct
electronic
equipment

electronic
equipment

control cabinet

control cabinet

KDDDS2

Fig. 5-14: Arranging the heat-exchanger unit on the roof of the control cabinet

Heat-exchanger unit on the
front of the control cabinet

incorrect

correct
control cabinet

control cabinet

air inlet

air inlet

air outlet

air
duct
cooling
unit

cooling
unit

electronic
equipment

electronic
equipment

KFDDS2

Fig. 5-15: Arranging the heat-exchanger unit on the front of the control cabinet

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Planning the construction of the control cabinet 5-14

DDS02.1/03.1

6

Electrical connections of the drive controller

6.1

General notes
• The signal lines must be routed separately of the supply lines due to
the interference.
• All signal lines should use plugin clamps or D subminiature plugin
connectors to facilitate any unit replacement that might be needed.
• Analog signals must be routed via shielded leads and their shields
mounted only to the drive controller.
• Mains, DC bus and motor leads may not be permitted to come into
contact with or be connected to the DC ±15V and DC +24V low voltages.
• If a high or interference voltage test of the electrical equipment of the
machine is to be conducted, then all connections must be clamped off
or removed entirely to avoid damage to the electronic components
(permissible per VDE 0113). The INDRAMAT drive components are
tested in accordance with the VDE 0160 high-voltage test.
• Electrostatic loads endanger electronic components. Body parts that
come into contact with these components or printed circuits, must first
be discharged by grounding. This means that the human body must be
discharged by touching a grounded object, soldering iron and parts
and tools must be placed on a conductive surface.
• Endangered components such as plugin modules must be stored or
transported in special packaging.
• Maintaining limit values for the transmission of interference (noise reduction) at the points of connection of the machine or plant, particularly
when operating in residential or light industrial areas, requires a shielded routing of the motor power cable or the use of a shielded motor
power cable. Proper installation of an interference filter, as recommended by INDRAMAT, into the mains supply conductors of the machine or plant is also advisable. The limit values as per class B (rf interference suppression grade N) as per EN 55011/3.91 and Table I
per EN 55014/1987 at the machine must be maintained. Further information can be found in the project planning manual „EMC in drive
and control systems“ (doc. no: 209-0049-4305-..).

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Electrical connections of the drive controller 6-1

DDS02.1/03.1

6.2

Connecting the basic unit
Basic unit DDS02.1-...

3

ground conn. to
the motor

1 ground connection to
supply unit

4 Motor
temperature monitor
Motor brake connection
DC +24V from external source

Fault reset key
2

Software module

three-phase current of
the motor power cable
1

X6

6

Status display
warning and error messages

S1

A1

5

DC bus connection
The connection starts
at the adjacent unit
via DC bus rails.

A2

6 Connection to adjacent
unit with bus rails.
The end plug supplied
with supply module
must be inserted in
the final module
(furthest distance).

H1

A3

U5

LL+

X5
ATTENTION!
NEVER REMOVE OR INSTALL THIS
PLUGS WHILE VOLTAGE IS APPLIED.
BLACK CABLE ON THE BOTTOM!
Verbindung nie unter Spannung
lösen bzw. stecken.
Schwarze Leitung immer unten!

X1
U1 U2

U3

U4
X2

X3
1

8 RS-232 interface
VT-100 connection
Terminal or PC

15

11
X4
8

9
1

9

motor feedback connection

7 - drive lockout connection
- acknowledge drive lockout
- ready
- 2 analog
diagnostic outputs
FADDS2GG

10 blower connection
only with DDS02.1-A...
Fig. 6-1: Front with designated connections for basic unit DDS02.1-...

For details on points x... see the following pages.

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Electrical connections of the drive controller 6-2

DDS02.1/03.1

Basic unit DDS03.1-...

1 ground connection
to supply unit

2 three-phase connection
of motor power cable
3 ground conn. to
motor

4 Motor
temp. monitor. conn.
Motor brake conn.
DC +24V from ext. source
Fault reset key
Software module

X6
U5

1
6

Status display
warning and error messages

1

A3 A2 A1

S1

2
3

5 DC bus conn.
The conn. comes
from adjacent unit
via DC bus rails.

6 Conn. to adj. unit
with bus rails.
The end plug in
the supply module
acces. kit must be
insert in final
modular unit
(furthest distance).

H1

X5a
LL+

X5b

ATTENTION!
NEVER REMOVE OR INSTALL THIS
PLUGS WHILE VOLTAGE IS APPLIED.
BLACK CABLE ON THE BOTTOM!
Verbindung nie unter Spannung
lösen bzw. stecken.
Schwarze Leitung immer unten!

X1
U1 U2

7 - drive lockout control
- acknowledge lockout
- ready
- 2 analog diagnostic
outputs

X2
X3

9 Motor feedback conn.

8 RS-232 interface
VT-100 connection
Terminal or PC

X4

FADDS3GG

Fig. 6-2: Front with connections designated of the basic unit DDS03.1-...

For details on points x... see the following pages.

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Electrical connections of the drive controller 6-3

DDS02.1/03.1

x Chassis earth connections to the supply unit
Ground connections

VPErde

Fig. 6-3: Chassis earth connection to the supply module
Core cross section

The cross section of the chassis earth connection


must be as big as the cross section of the mains supply line



but not smaller than 10 mm

2

Earth loops should be avoided, if possible, as intermeshing causes interference and can make fault clearance more difficult.

yz{ Connecting the motor power cable to the drive controller
Use INDRAMAT motor power cables for the lines between the drive controller and the AC motors.
Motor power cable

The INDRAMAT motor power cable contains:
• three lines for the motor power connection
• one line for the protective conductor connection
• a separately shielded pair of cables for motor temperature monitoring
(PTC resistor in the motor)
• a separately shielded pair of cables for the motor brake
• a total shield for power cables IKG. Applies if being operated within
residential or light industrial areas to maintain the limit values for the
emission of interference (rf interference suppression). Otherwise, a
totally shielded routing of the power supply may be necessary.
The motor power cable is a ready-made cable and available from Indramat. A cable can also be made out of four individual leads (three phases,
1 protective conductor), with a separately conducted, shielded thermal
resistance and brake connection cable. For further information on technical data, connections and cross sections, please check the motor
description and the cable catalog.

Maximum cable length

The maximum cable length equals 75 meters if INDRAMAT cables are
used.

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Electrical connections of the drive controller 6-4

DDS02.1/03.1

A1 A2

SBX6DDS2

UB

TM-

TM+

0VB
6

3

2

1

5

4

BR

DDS 2.1

0VB

DDS02 motor power connection

X6

A3

0VExt

24V

H

E

G

F

D

C

B

A

24VExt

U

M

3

holding
brake

PTC

MDD
servo motor

Fig. 6-4: Motor power, holding brake and motor temperature monitoring connections in the DDS02.1

DDS02 power cable connection

Motor power cable

X6

shield

X6
A1

S1
H1

TM+ 1
TM- 2
UB
3
BR
4
0VB 5
0VB 6

1)
5 or wh.
6 or br

1)

2)
7 or red 1)
1)
8 or blk.
2)

A2

A3

0VExt.

U5

24VExt.±10%

1) The strands out of the motor power cable are numerically labelled.
Exception: the strands of IN 253 are color coded.
2) External power source of holding brake equals:
24V direct voltage ±10%.
A cross section of at least 0.75 mm2 is recommended.
DDS2SER

Fig. 6-5: Motor power cable connection to the DDS02

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Electrical connections of the drive controller 6-5

SBX6DDS3

0VB

TM-

UB

6

3

2

0VB

BR

5

X5

4

A2

A3
4

3

2

1

A1

DDS 3.1

1

DDS03 motor power cable
connection

TM+

DDS02.1/03.1

X6

0VExt

24V

H

E

G

F

D

C

B

A

24VExt

U

M

3

Holding
brake

PTC

MDD
Servo

Fig. 6-6: Motor power, holding brake and motor temperature monitor connections
with the DDS03.1

DDS03 power cable
connections

Motor power cable

X6

Shield

X6

1
6

A3 A2 A1

S1

X5a

TM+ 1
TM- 2
UB
3
BR
4
0VB 5
0VB 6

1)
5 or wh.
6 or br

1)

2)
7 or red 1)
1)
8or blk.
2)

H1
0VExt.

U5

24VExt.±10%

1) The motor power cable cores are numerically identified.
Exception: the cores of cable IN 253 are color coded.
2) The external power source of the holding brakes equals:
24V direct current ±10%.
A cross section of at least 0.75 mm2 is recommended.
DDS3SER

Fig. 6-7: Motor power cable connections to the DDS03 drive controller

Connecting the power cable to
the motor

In terms of the motor, the connection takes the form of either a connector
or terminal box.
The DDS drive controller connections are outlined in the motor documentation as well as the circuitry with precise clamp designations.

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Electrical connections of the drive controller 6-6

DDS02.1/03.1

{ Connector X6: Holding brake, motor temperature monitoring
It is only necessary to connect external DC 24V if a motor holding brake is
used.
The current consumption of the holding brake is listed in the motor documentation.
The holding brake of the MDD/MKD motors is not a service brake. It wears down after approximately 20,000 motor revolutions against the closed
brake disc.

Note:

Controlling the motor holding
brake

To release the holding brake it is necessary to apply DC +24V
+/- 10 % directly to the motor. The voltage to release the motor
brake is applied at X6/3 and X6/6. It must be certain that the
brake will effectively release even if longer motor power cables
are used (voltage drop with longer motor power cables can be
compensated by higher voltages (to DC +28V) at X6/3 and
X6/6).

The drive controller controls the motor holding brake.

| DC bus voltage connection
Adjacent drive controllers are normally connected via the DC bus rails
which are in the accessories kit E .. - DDS 2. If DC bus rails are not needed for a specific connection, then the connection can be established via
stranded leads that are as short as possible (maximum length of 1 meter). The cross section of the lead depends on the supply unit or the DC
bus continuous output.
DC bus rails must be used with the DDS02.1-.150-... and DDS02.1-.200... drive controllers.

Supply unit

DC bus continuous
ouput in kW

Lead cross section
2
in mm

TVM 1.2-...

7.5

4

TVM 2.2-.../TVM 2.4-...

7.5

4

KDV 1.3-...

30

25

KDV 2.2-.../KDV 2.3-...

30

25

KDV 3.1-...

30

25

KDV 4.1-...

30

25

TVD 1.2-08-3

7.5

TVD 1.2-15-3
15
Fig. 6-8: DC bus connection - required cross sections

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

4
10

Electrical connections of the drive controller 6-7

DDS02.1/03.1

} Connector X1: Bus connections
The control electronics of the drive controllers are supplied via connector
X1. The connection starts at the supply unit and runs to the drive controllers with the help of the bus cable. The bus cable is part of the electrical
connecting kit E . . -DDS 2. Insert the bus cable, with the black core at the
bottom, into connector X1. Insert the end connector supplied in the kit
(e.g.,: E3-TVD) of the supply unit into the last unit (the unit physically
furthest away from the supply unit). In special cases it is possible to use a
special bus cable with a maximum length of one meter.

mains

supply unit

GVDDS3

end plug
L-

L-

L+

ATTENTION!
NEVER REMOVE OR INSTALL THIS
PLUGS WHILE VOLTAGE IS APPLIED.
BLACK CABLE ON THE BOTTOM!
Verbindung nie unter Spannung
lösen bzw. stecken.
Schwarze Leitung immer unten!

L+

ATTENTION!
NEVER REMOVE OR INSTALL THIS
PLUGS WHILE VOLTAGE IS APPLIED.
BLACK CABLE ON THE BOTTOM!
Verbindung nie unter Spannung
lösen bzw. stecken.
Schwarze Leitung immer unten!

black
strand of
the bus
conn.
cable
Fig. 6-9: Connecting the units via flat-ribbon cables and DC bus rails

conn. X1

1)
" UD " - Signal:
High = DC bus volt.
UD exceeds
permissible
minimum
value
" BB " - Signal:
High = drive module
ready
SBX1DDS2

1
2
3
4
5
6
7
8
9
10
11
12

bus connection

U D 1)
BB 1)
+15V
0V M
0V M
0V M
0V M
-15V
-15V
0V
+24V

Fig. 6-10: Connector assignment X1

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Electrical connections of the drive controller 6-8

DDS02.1/03.1

~ Connector X3
X3

1

AK1
OVM
AK2
0VM

2
3

X2

4
5
6

X3

Bb
Bb
AS+
ASASQ
ASQ

7
8
9
10
11

Analog
diagnostic
outputs
ready
to operate
contact
starting
lockout

X3
X4
SBX3DDS2

Fig. 6-11: Connector assignment X3

Analog diagnostic outputs AK1,
AK2

The analog diagnostic outputs are analog outputs via which drive-internal
variables are generated for test purposes, e.g., when commissioning. For
further details on analog diagnostic outputs, please see the application
description.
Current load capacity:
Output voltage:

Ready to operate contact Bb

4 mA
DC 10 V

If ready to operate contact „Bb“ closes, then the drive controller is ready to
receive power. The „Bb“ closes if the control voltage is on and all monitoring functions are signalling a ready state.
The „Bb“ can be evaluated in the control, for example, so that the control
immediately recognizes which drive controller in the drive package has
had a power failure.
Switching capacity: DC 24 V, 1 A (short-term and continuous)

Note:

The direct connection of a contactor coil to the Bb contact is
not permitted as the contact could be overloaded by excessive
short-term currents after frequent switching sequences thus
causing it to break down.
The use of varistors as protective circuits is not acceptable as
these require ever-higher levels of current over the course of
their service life. This could cause early failures of the connected components and ultimately the unit as well.

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Electrical connections of the drive controller 6-9

DDS02.1/03.1

Starting lockout
AS+, AS-, ASQ, ASQ

The starting lockout represents a safety device to prevent unintentional
startups of the connected motors in the event of a fault. It makes sure that
the separately working areas of a machine or plant are securely switched
off.

Note:

The starting lockout is note intended to bring to a standstill
axes that are moving.

For further information on this topic, see the documentation on „Starting
lockout - functions in drive controller DDS“ (doc. no: 209-0069-4313-XX).
AS+,AS-:

control input for relay coils
voltage: DC 20 .... 30 V
power: 1.5 W

ASQ, ASQ:

potential-free response contact which acknowledges the
activation of a starting lockout to an external control.
Switching power: DC 24 V, 1 A (short-term and
continuous)

To activate the starting lockout, apply a voltage of DC +20 ... 30 V between input terminsl AS+, AS-. The switching of the startup relay in the drive
controller is confirmed by closing the potential-free response contact
(output ASQ - ASQ) at the external control.

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Electrical connections of the drive controller 6-10

DDS02.1/03.1

 Connector X2: interface RS232

Service cable IKS0391

DDS 2.1

connector X2
15 pin D-Submin. conn.
X2
15

Signal
TxD
RxD
RTS
CTS
SGND

8

1

serial
interface:
V24, RS 232C

9-pin D-Submin. male
Pin
3
2
7
8
5
4
6

Pin
2
3
4
5
7

housing

Signal
TxD
RxD
RTS
CTS
SGND
DTR
DSR

9

5
1

Order code:
SBSKDDS2

(Example) IKS 0391/ . . .
Cable

length in meters
2, 5, 10 or 15m

Fig. 6-12: Service cable

Service cable IKS0391 is needed to commission drive controllers with
ANALOG interface (configurations: DA..-..-FW and RA...-..-FW), as this
interface is used for parametrization during startup with the use of a terminal / terminal program.

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Electrical connections of the drive controller 6-11

DDS02.1/03.1

€ Connector X4: Motor feedback
The motor feedback is connected at terminal X4.
Independent of the rated current, there are two types of drive controllers (basic units). Digital Servo Feedbacks (DSF) only may be
connected to motor feedback terminal X4, of the type, whilst only
Resolver feedbacks (RSF) may be connected to the other.
Pre-requisites:
• The motors with a digital servo feedback (DSF) must be operated with
DDSxx.1-xxxx-D drive controllers.
• Motors with a resolver feedback (RSF) must be operated with
DDSxx.1-xxxx-R drive controllers.

Motor

Drive controllers
DDSxx.1-xxxx-D

Drive controllers
DDSxx.1-xxxx-R

MDDxxxx-x-xxx-xxL-xxxx

can be connected

-

MDDxxxx-x-xxx-xxM-xxxx

can be connected

-

MDDxxxx-x-xxx-xxG-xxxx

-

can be connected

MDDxxxx-x-xxx-xxK-xxxx

-

can be connected

MDDxxxx-x-xxx-xxS-xxxx

can be connected

-

MDDxxxx-x-xxx-xxT-xxxx

can be connected

-

MKDxxxx-x-xxx-xxG-xxxx

-

can be connected

MKDxxxx-x-xxx-xxK-xxxx

-

can be connected

LAF

can be connected

-

LAR

can be connected

-

L, S = digital servo feedback (DSF)
M, T = digital servo feedback with integrated multiturn absolute encoder (DSF)
G = resolver feedback (RSF)
K = resolver feedback with integrated pulse generator absolute encoder (RSF)

Fig. 6-13: Permitted motor/controller combinations

The use of INDRAMAT feedback cables is recommended to connect drive controller and servo motor feedback.
The LAF linear motor and the LAR linear motor (with housing) have no
motor feedback of their own. These motors are operated via an external
linear scale. These linear scales are not connected to the feedback terminal X4 of the basic unit but rather to the plugin module needed for the linear scale. For further information, please see the motor documentation.
Maximum cable length

If INDRAMAT feedback cables are used, then maximum length is 75
meters.
For further information on these cables, see the motor documentation.

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Electrical connections of the drive controller 6-12

DDS02.1/03.1

Drive
controller

MDD
Servo motor
1)

X4

Feedback conn. INS0513

1)

0VM

4

10

S-

2

6

S+

9

5

C-

3

1

C+
UG

10

8

12

12

FS

14

3

SCL

7

2

SDI

15

4

SDO

8

7

1

9

Digital Servo Feedback

Feedback connection X4 with
DDSxx.1-xxxx-D for digital
servo feedbacks

X4
8
7
6
5
4
3
2
1

SDI 15
FS 14
13
UG 12
11
C+ 10
S+ 9

SDO
SCL
0VM
CSShield

1) Apply shield to connector housing

SBX4DDSD

!

Fig. 6-14: Connector assignment of X4 in the DDSxx.1-xxxx-D

Drive
controller
1)

X4

1)

MKD
Servo motor
Feedback conn. INS0513

0VM/R3

4

10

S3

2

6

S1

9

5

S4

3

1

S2
R1

10

8

12

12

FS

14

3

SCL

7

2

SDI

15

4

SDO

8

7

1

9

Resolver feedback

Feedback connection X4 with
DDSxx.1-xxxx-R for resolver
feedback

X4
SDI 15
FS 14
13
R1 12
11
S2 10
S1 9

8
7
6
5
4
3
2
1

SDO
SCL
0VM/R3
S4
S3
Shield
SBX4DDSR

1)

Apply shield to connector housing !

Fig. 6-15: Connector assigment of X4 with the DDSxx.1-xxxx-R

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Electrical connections of the drive controller 6-13

DDS02.1/03.1

 Connectors X13, X14a, X14b: heatsink blower only with DDS02.1-A...
Connectors X13, X14a, X14b can only be found in DDS 2.• - A… drive
controllers (see dimensional sheet illustration).

Adjacent unit

Adjacent unit

N

L1

X13 X14b

X14a

F6
Power supply comes
from adjacent unit
via cable;
cable is part of
accessories kit
E • • - DDS 2.

M
Blower unit
LE 4

APLDDS2A

Fig. 6-16: Connecting the blower to the DDS 2.1-A... drive controller

The DDS 2.•-A… should preferrably be connected to an adjacent unit with
a 230 V or 115 V blower connection. If this is not possible, then a connector is required (part no. 219118). This connector will be delivered as of
calendar week 10/95 along with the LE4 blower unit.

Blower unit

Type

Supply voltage
in V

Frequency Maximum poin Hz
wer consumption
in VA

LE4 220

AC 230 (+6/-10%)

50...60

70

0.630A/250
E

LE4 115

AC 115 (±10%)

50...60

70

1.250A/250
E

Fuse F6

Fig. 6-17: Technical data of the LE4 blower unit

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Electrical connections of the drive controller 6-14

DDS02.1/03.1

Summary terminal diagram
Additional modules connected
with electrical connecting accessories

Signal
processing

DC bus voltage

(12 pin, bus cable)

L+

L-

12

1

X5

X1

(conductor rails)

Drive controller
DDS 2.1 - .... - D ...
U5

U4
Aux. plugin
module

Software
module

U3
Aux. plugin
module
U2
Aux. plugin
modules

1)

X4

1)

0VM

AS+

2
4

SDO

8

7

1

9

7

Bb

7
15

12

8

Bb

3

SDI

9

14

6

Starting
lockout

MDD Motor

AS-

8

SCL

10

1

FS

ASQ

5

3
10

11

9

C+
UG 12

ASQ

6

C-

X3

10

2

S+

U1
Command comm.
mod.

4

S-

Digital Servo Feedback

Connection of optional
interface module per
relevant terminal
diagrams.

5
4

AK2

3

0VM

2

X6
0VB 6

1

AK1

UB 3
TM- 2
TM+ 1

CTS

RxD
TxD

1

Holding
brake

+ 24V
11

C

A3

B

A2
12

0VL
10

8,9 - 15V

+ 15V

4-7 0VM

D

BB

TxD

2

3

3

2

RxD

F

RTS

UD

4

1

RTS

0VM

RS 232
interface

5

G

BR 4

10

CTS

E

0VB 5

X2

H

U

Analog
diagnostic
outputs

PTC

0VM

L-

X1

L+

A

A1

M

3

X5

Power of drive
components
via the elec. conn.
access.

DC 300V
power
voltage

Bus connecting
cable

(conductor rails)

24VExt
0VExt

Versorgungsmodul

1)

24V

black

APDDS2_D
1)

Apply shield to connector housing!

Fig. 6-18: Summary terminal diagram for basic unit DDS02.1-... with MDD motor

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Electrical connections of the drive controller 6-15

DDS02.1/03.1

The summary terminal diagram of the DDS02.1-...-D shows that a MDD
motor with digital servo feedback (DSF) has been connected (see Fig. 618). This total terminal diagram serves as an example for this motor/controller combination.
The summary terminal diagram must, of course, be altered with different
motor/controller combinations.

Nr.

Motor

Controller

1

MDD with DSF and DDS02.1-....-D
connector

no difference

2

MDD with DSF and DDS03.1-....-D
connector

no slots U3 and U4

3

MDD with RSF
and
connector

DDS02.1-....-R

terminal designations for X4 see Fig. 6-15

4

MDD with RSF
and
connector

DDS03.1-....-R

no slots U3 and U4
terminal designations for X4 see Fig. 6-15

5

MKD with RSF
and
terminal box

DDS02.1-....-R

terminal designations for X4 see Fig. 6-15
See motor documentation for details on connecting motor feedback
and motor power connection.

6

MKD with RSF
and
terminal box

DDS03.1-....-R

terminal designations for X4 see Fig. 6-15
no slots U3 and U4
See motor documentation for details on connecting motor feedback
and motor power connection.

7

LAF

DDS02.1-....-D

X4 free, the scale is connected to the plugin module.
See motor documentation for details on connecting motor scale and
motor power connection.

8

LAR with
connector

DDS02.1-....-D

X4 free, the scale is connected to the plugin module. See motor
documentation for details on connecting motor scale and motor power connection.

DSF = digital servo feedback

Difference to summary terminal diagram (see Fig. 6-18)

RSF = resolver feedback
Fig. 6-19: Differences to the summary terminal diagram

6.3 Connecting the plugin module
Both the terminal diagrams and the technical data on the plugin modules
are outlined in document „DIAX02 Plugin modules for digital intelligent
drive controllers“.

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Electrical connections of the drive controller 6-16

DDS02.1/03.1

7

Accessories
Connection accessories kit
E..-DDS..

The electrical connecting accessories kit E..-DDS.. simplies the task of
connecting a drive package made up of various units with various allocations.
To be able to select this kit E..-DDS.. the precise allocation of the units
inside the control cabinet must be known.
The DDS02 drive controller generally needs kit E..-DDS 2.
The DDS03 drive controller generally needs kit E..-DDS 3.

Connector kit S..-DDS 2

Connector kit S..-DDS 2 is also needed. It depends on the unit configuration. Connector kit S..-DDS 2 can be selected for the respective configuration as per Fig. 8.3.
Connector kit S..-DDS 2 is identical for both DDS02 and DDS03.

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Accessories

7-1

DDS02.1/03.1

7.1

Electrical connecting kit E..-DDS 2
The following illustration is intended to assist in determining which E..DDS 2 kit is needed to connect adjacent units.

Electrical connection
accessories
for drive controller types:
DDS 2.• - W
DDS 2.• - F
DDS 2.• - A
connection to
following units

orientation to the right
DDS 2.• - W
DDS 2.• - F

Type designation

DDS 2.• - A

orientation to the left
DDS 2.• - W
DDS 2.• - F

Type designation

DDS 2.• - A

Type designation

KDV 1
KDV 2
KDV 3
KDV 4
KVR 1
TVD
TVM
TVR 2
TVR 3

E9-DDS 2
E9-DDS 2
E1-DDS 2
E1-DDS 2
E6-DDS 2
E1-DDS 2
E3-DDS 2
E6-DDS 2
E1-DDS 2

E11-DDS 2
E11-DDS 2
E13-DDS 2
E13-DDS 2
E15-DDS 2
E1-DDS 2
E17-DDS 2
E6-DDS 2
E1-DDS 2

E5-DDS 2
E5-DDS 2
E2-DDS 2
E2-DDS 2
E7-DDS 2
E2-DDS 2
E3-DDS 2
E7-DDS 2
E2-DDS 2

E12-DDS 2
E12-DDS 2
E14-DDS 2
E14-DDS 2
E16-DDS 2
E2-DDS 2
E17-DDS 2
E7-DDS 2
E2-DDS 2

DDS 2.• - W
DDS 2.• - F
DDS 2.• - A
DDS 3
KDA
KDF
KDS
TDA
TDM 1
TFM
TDM 3/4
TDM 6/7

E3-DDS 2
E3-DDS 2
E3-DDS 2
E8-DDS 2
E4-DDS 2
E9-DDS 2
E9-DDS 2
E4-DDS 2
E3-DDS 2
E3-DDS 2
E8-DDS 2
E8-DDS 2

E3-DDS 2
E3-DDS 2
E17-DDS 2
E8-DDS 2
E18-DDS 2
E11-DDS 2
E11-DDS 2
E4-DDS 2
E3-DDS 2
E3-DDS 2
E8-DDS 2
E8-DDS 2

E3-DDS 2
E3-DDS 2
E3-DDS 2
E10-DDS 2
E5-DDS 2
E5-DDS 2
E5-DDS 2
E5-DDS 2
E3-DDS 2
E3-DDS 2
E10-DDS 2
E10-DDS 2

E3-DDS 2
E3-DDS 2
E17-DDS 2
E10-DDS 2
E12-DDS 2
E12-DDS 2
E12-DDS 2
E5-DDS 2
E3-DDS 2
E3-DDS 2
E10-DDS 2
E10-DDS 2

The DDS 2.• - A should preferrably be connected to an adjacent unit with 220 V or 115 V blower connection.
If this is not possible, then connector 219 118 will be needed for the blower connection to DDS 2.• - A.
This connetor will be included with the LE4 blower unit as of calendar week 10/95.
ZubDDS2

Fig. 7-1: Summary of electrical kits E..-DDS 2

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Accessories

7-2

DDS02.1/03.1

Connector for the
• motor temperature monitor
• motor brake
•DC 24V external power source
6-pin plugin terminal
(part no. 241672)
1

Parts for
connecting
individual
units

2
3
4
5

S1

A1

A2

Power connection
(DC bus rails)

6

X6

H1

A3

L-

U5

L+

X5

Bus connection
ATTENTION!
NEVER REMOVE OR INSTALL THIS
PLUGS WHILE VOLTAGE IS APPLIED.
BLACK CABLE ON THE BOTTOM!
Verbindung nie unter Spannung
lösen bzw. stecken.
Schwarze Leitung immer unten!

X1
U1 U2

U3

U4
X2

2

H3
CHK

11-pin plugin terminal
(part no. 241592)
1

X3

H2

Input and output
connectors

8

1
0

9

6

S3 HIGH

7

5

1
0

9

6

7

8

X 11 RX

10 11

5

S2 LOW

8

7

9

3
4

Length dependent on
• type of adjacent unit
• distance to unit

6

4

X4

E1
E2
E3
E4
E5

X 12

Power source connection
for external blowers in
DDS 2.• - A... units

5

3

4

X 10 TX

3

2

2

+UL
0VL

AZEDDS2A

Fig. 7-2: Parts of the electrical accessories kit E..-DDS 2

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Accessories

7-3

DDS02.1/03.1

7.2

Electrical accessories kit E..-DDS 3
The following illustration is intended to assist in determining which E..DDS 3 kit is needed to connect adjacent units.

The electrical connecting accessories required
*) the unit to which the
DDS 3 drive controller is
to be connected

orientation to the right

orientation to the left

DDS 3

DDS 3

*)

*)

Type designation

Type designation

Type designation

KDV 1
KDV 2
KDV 3
KDV 4
KVR 1
TVD
TVM
TVR 3
TVR 2

E10-DDS 3
E10-DDS 3
E1-DDS 3
E1-DDS 3
E7-DDS 3
E1-DDS 3
E3-DDS 3
E1-DDS 3
E7-DDS 3

E6-DDS 3
E6-DDS 3
E2-DDS 3
E2-DDS 3
E8-DDS 3
E2-DDS 3
E4-DDS 3
E2-DDS 3
E8-DDS 3

DDS 2
DDS 3
KDA
KDF
KDS
TDA
TDM 1
TFM
TDM 3/4
TDM 6/7

E3-DDS 3
E9-DDS 3
E5-DDS 3
E10-DDS 3
E10-DDS 3
E5-DDS 3
E3-DDS 3
E3-DDS 3
E9-DDS 3
E9-DDS 3

E4-DDS 3
E9-DDS 3
E6-DDS 3
E6-DDS 3
E6-DDS 3
E6-DDS 3
E4-DDS 3
E4-DDS 3
E9-DDS 3
E9-DDS 3

AZDDS3

Fig. 7-3: Summary of electrical connecting kit E..-DDS 3

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Accessories

7-4

DDS02.1/03.1

Parts to
connect
individual
units

X6
U5

1
6

S1

Motor power connector
4-pin plugin terminal
(part no. 252821)

H1

Power connection

Connector for
- motor temperature monitor
- motor brake
- DC 24V ext. power source
6-pin plugin terminal
(part no. 241672)

X5a

DC bus rails

LL+

Bus connection

X5b
DDS 3.1-W030-D
K30/95

SN263508-04604

A00

X1

U1 U2
X2

Length dependent on
• type of adjacent unit
• distance to adjacent unit

X3

Input and output
connectors
11-pin plugin terminal
(part no. 241592)
X4

AZEDDS3

Fig. 7-4: Parts of the connecting kit E..-DDS 3

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Accessories

7-5

DDS02.1/03.1

7.3

Connector kit for various configurations
There is a connector kit S . . - DDS 2 for each unit configuration. The
connector for the plugin modules inserted into the configured drive controllers and the motor feedback connector (X4) are in this kit.

Configuration

Connector kit

Configuration

Connector kit

Configuration

Connector kit

DA01-01-FW

S 1-DDS 2

DL41-01-FW

S81-DDS 2

2) 3)

DS60-50-FW

S57-DDS 2

1) 3)

DA02-01-FW

S 1-DDS 2

DL42-01-FW

S82-DDS 2

2) 3)

DS61-00-FW

S87-DDS 2

1)

DA03-01-FW

S 8-DDS 2

DL43-01-FW

S80-DDS 2

2) 3)

DS62-00-FW

S87-DDS 2

1)

DA06-01-FW

S14-DDS 2

DL45-01-FW

S 9-DDS 2

2) 3)

DS63-00-FW

S53-DDS 2

1)

DA07-02-FW

S86-DDS 2

DS01-02-FW

S 2-DDS 2

1)

RA01-02-FW

S 1-DDS 2

DA10-01-FW

S14-DDS 2

DS03-02-FW

S 3-DDS 2

1)

RA02-02-FW

S 1-DDS 2

DA11-01-FW

S84-DDS 2

DS04-03-FW

S 3-DDS 2

1)

RA11-01-FW

S84-DDS 2

DA12-01-FW

S84-DDS 2

DS05-01-FW

S 7-DDS 2

1)

RA12-01-FW

S84-DDS 2

DA14-01-FW

S14-DDS 2

DS06-02-FW

S62-DDS 2

1)

RC01-01-FW

S32-DDS 2

DC01-01-FW

S32-DDS 2

DS08-01-FW

S22-DDS 2

1)

RC02-01-FW

S37-DDS 2

DC02-01-FW

S37-DDS 2

DS09-01-FW

S21-DDS 2

1)

RC03-01-FW

S35-DDS 2

DC03-01-FW

S35-DDS 2

DS13-01-FW

S 3-DDS 2

1)

RL01-01-FW

S 9-DDS 2

2)

DC04-01-FW

S76-DDS 2

DS22-02-FW

S29-DDS 2

1)

RL02-01-FW

S10-DDS 2

2)

DL01-01-FW

S 9-DDS 2

2)

DS24-03-FW

S63-DDS 2

1)

RL03-01-FW

S11-DDS 2

2)

DL02-01-FW

S10-DDS 2

2)

DS25-01-FW

S27-DDS 2

1)

RL04-01-FW

S12-DDS 2

2)

DL03-01-FW

S11-DDS 2

2)

DS37-01-FW

S65-DDS 2

1)

RL05-01-FW

S13-DDS 2

2)

DL04-01-FW

S12-DDS 2

2)

DS40-02-FW

S 3-DDS 2

1)

RL08-01-FW

S17-DDS 2

2)

DL05-01-FW

S13-DDS 2

2)

DS41-00-FW

S66-DDS 2

1)

RL09-01-FW

S18-DDS 2

2)

DL08-01-FW

S17-DDS 2

2)

DS45-00-FW

S53-DDS 2

1)

RL10-01-FW

S33-DDS 2

2)

DL09-01-FW

S18-DDS 2

2)

DS46-00-FW

S78-DDS 2

1)

RL20-01-FW

S32-DDS 2

2)

DL10-01-FW

S33-DDS 2

2)

DS46-01-FW

S78-DDS 2

1)

RL21-01-FW

S32-DDS 2

2)

DL11-01-FW

S12-DDS 2

2)

DS47-00-FW

S85-DDS 2

1)

RL22-01-FW

S37-DDS 2

2)

DL12-01-FW

S13-DDS 2

2)

DS47-01-FW

S85-DDS 2

1)

RL23-01-FW

S37-DDS 2

2)

DL13-01-FW

S33-DDS 2

2)

DS48-00-FW

S 7-DDS 2

1)

RL24-01-FW

S35-DDS 2

2)

DL14-01-FW

S12-DDS 2

2)

DS50-00-FW

S63-DDS 2

1)

RL25-01-FW

S35-DDS 2

2)

DL20-01-FW

S32-DDS 2

2)

DS51-00-FW

S60-DDS 2

1)

RL26-01-FW

S34-DDS 2

2)

DL21-01-FW

S32-DDS 2

2)

DS51-01-FW

S60-DDS 2

1)

RL27-01-FW

S34-DDS 2

2)

DL22-01-FW

S37-DDS 2

2)

DS53-00-FW

S60-DDS 2

1)

RL28-01-FW

S36-DDS 2

2)

DL23-01-FW

S37-DDS 2

2)

DS54-00-FW

S77-DDS 2

1)

RL29-01-FW

S36-DDS 2

2)

DL24-01-FW

S35-DDS 2

2)

DS55-00-FW

S29-DDS 2

1)

RL30-01-FW

S76-DDS 2

2)

DL25-01-FW

S35-DDS 2

2)

DS56-00-FW

S30-DDS 2

1)

RL31-01-FW

S76-DDS 2

2)

DL26-01-FW

S34-DDS 2

2)

DS57-00-FW

S85-DDS 2

1)

RS01-03-FW

S 2-DDS 2

1)

DL27-01-FW

S34-DDS 2

2)

DS57-01-FW

S85-DDS 2

1)

RS03-03-FW

S 3-DDS 2

1)

DL28-01-FW

S36-DDS 2

2)

DS58-00-FW

S66-DDS 2

1) 3)

RS04-03-FW

S 3-DDS 2

1)

DL29-01-FW

S36-DDS 2

2)

DS58-50-FW

S66-DDS 2

1) 3)

RS16-02-FW

S65-DDS 2

1)

DL30-01-FW

S76-DDS 2

2)

DS59-00-FW

S57-DDS 2

1) 3)

RS18-02-FW

S30-DDS 2

1)

DL31-01-FW

S76-DDS 2

2)

DS59-50-FW

S57-DDS 2

1) 3)

DL40-01-FW

S80-DDS 2

2) 3)

DS60-00-FW

S57-DDS 2

1) 3)

1) If drive controllers with SERCOS interface are used, then the fiber optic cable connections (cables and connectors or readymade cables) must be ordered.
2) If drive controllers with integrated single-axis positioning controls are used, then the connectors for the positioning module DLC
1.1 are not in kit S..-DDS 2. They must be ordered if needed.
3) If drive controllers with profibus interfaces are used, then the connector for the profibus is not part of the kit.

Fig. 7-5: Determining the connector kit for a specific unit configuration

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Accessories

7-6

DDS02.1/03.1

7.4

Service cable - IKS0391
Service cable IKS0391 is needed to startup drive controllers with
ANALOG interface (configuration: DA..-..-FW and RA...-..-FW) (see Fig.
6-12), as via this interface parametrization during startup is conducted via
a terminal / terminal program.

7.5

Selecting the fiber optic cable connections
The SERCOS interface implements a fiber optic cable to communicate
between drive and control.
For further information on the topic „Fiber optic cables“ please see in the
application description „Fiber optic cable handling“ (doc. no. 209-00904101-xx).
In this document, the following points are discussed:
• general information about such cables
• basic planning guidelines for optical transmission systems
• routing guidelines
• damping measurements of ready-made fiber optic cables
• available FSMA plugin connectors and fiber optic cables
• guidelines on making FSMA connetors
• tools for making fiber optic cables
Use the following illustration to determine the order data of the fiber optic
cables for the entire system.

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Accessories

7-7

DDS02.1/03.1

CNC

IKO 985 / . . . /(for ext. routing)

SERCOS
Interface

length in
1

1

1

6

6

6

6

DDS 2

LWL ring

1

DDS 2

DDS 2

DDS 2

ø 2mm
1

1

1

1

0

0

3
5

5

6

6

6

6

9

2

4

1

1

3
4

5

5

0

2
4

4

9

1

3

0

2

9

3

9

1
2

8

7

8

7

8

7

8

7

2

3

2

3

2

3

2

3

8

1

1

0

1

1

0

7

0

0

8

9

9

7

9

9

8

ø 6mm

11

7

11

6

6

6

6

7

8

IKO 982/ . . .

5

5

5

5

11

4

4

4

4

11

depends on unit
arrangement

IKO 982 / . . .
LWL plugin coupling unit
(control cabinet leadthrough)
part no. 252 524

length in meters

The LWL cable required
*) The unit to which
the DDS is to be
connected via the
LWL (fiber optic)
cable.

allocation to the right
*)

allocation to the left
DDS

DDS

*)

LWL cable
type (part

LWL cable
type (part

DDS 2, DDS 3

IKO 982/0,25 (239 183)

IKO 982/0,25 (239 183)

TDA

IKO 982/0,3 (239 184)

Type designation

AZLWLSER

Fig. 7-6: Selecting the ready-made fiber optic cables for a SERCOS ring

7.6

Mechanical accessories for DDS02.1-A***-*
Blower unit
LE4 220, LE4 115

The blower unit LE4 contains the parts labelled with (1) in Fig. 5-7.
• LE4 220 for a supply voltage of AC 220V, 50...60 Hz
• LE4 115 for a supply voltage of AC 115V, 50...60 Hz

Mechanical accessories M1-KD

Accessories M1-KD contain the parts labelled with a (2) Fig. 5-7.

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Accessories

7-8

DDS02.1/03.1

7.7

Mechanical accessories for DDS02.1-F***-* drive
controllers (with liquid cooling)
Accessories kit SH - FL

82

159

136

74

70

Cover

2x M5x12
5.5
7
50

MBzub

Fig. 7-7: Dimensional sheet for accessories kit SH - FL

Accessories kit M2-F

approx. 50 (mounted)

coupling
SW 14
SW 19

MBsteck

Fig. 7-8: Dimensional sheet for accessories kit M2-F

Accessories kit M2-F contains two coupling units to connect the coolant
equipment to the drive controller.

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Accessories

7-9

DDS02.1/03.1

8

Powering up the power sections via charging
resistors
Powering up the power section via charging resistor „RL “ is an option
which must be selected:
Use supply unit TVM 2.1 / 2.4 under the following conditions:
– Power transformer & gt; 10 KVA
– Power transformer & gt; 2.5 KVA and auxiliary capacitance
– Power transformer is dropped because of 220 V three-phase mains
Use supply unit KDV 1.3 under the following conditions:
– Power transformer & gt; 50 KVA
– Power transformer & gt; 35 KVA and auxiliary capacitance
– Power transformer is dropped because of 220 V three-phase mains

Note:

Compare ready to operate

The Bb contact of the DDS2 drive controller closes if all monitoring functions signal a ready steady. Unlike the analog drive
controllers TDM and KDS, the Bb contact can no longer be
used to bridge the charging resistors.

Bb contact is closed with TDM
and KDS drive controllers if:

Bb contact closed with DDS
drive controllers if:

Drive controller ready to output power.

DDS drive controller ready for power
to be switched on.

(Bb can be used as signal to bridge
charging resistors.)

Bb cannot be used as signal to
bridge charging resistors.)

Contact „Bb“ closes if power is
switched on and all monitoring
functions are signalling that all is in
order.

Contact „Bb“ closes if control voltage is switched on and all monitoring functions are signalling that all is
in order.

Diagnosis: any unit that has failed in
the drive package cannot be determined via the Bb contact.
Fig. 8-1: Compare ready to operate

Diagnosis: any unit that has failed in
the drive package can be determined via the Bb contact

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Powering up the power sections via charging resistors

8-1

DDS02.1/03.1

Control circuits for KDV 1.3, TVM 2.1 and TVM 2.4 supply units:
• with charging resistors
• with DC bus dynamic brake
L1
L2
L3
F1

K7

Drive
controller
DDS 2

Supply unit
KDV 1.3
TVM 2.1

RL

T1

L-

L-

L+

L1
L2
L3

K1

L+

RK

R1

R2

Attention: make sure the
connection is phase

R3

R4

K2

Control voltage

1

2

3

4

5

7

6

8

DC
24V

K1

K3
S2
Endl
posit

X10/6
KDV / Bb1
TVM / Bb1

RF

X10/7

S1
E-stop
S3 safety
doors
S4
Off

NC

RF input
with ANALOG interface
(DAE 1.1 X13/4; DAA X15/4)

K2
S5
On

K2

K1

K6
K1

K2

K7

K6

K1

K3

U
PE

Bb1 = Supply module ready (drive system)
F1 = Power supply fuse
K1 = Mains contactor
K2 = DC bus dynamic brake contactor
K3 = Bb1 isolated
K6 = Pickup delay approx. 500 ms
K7 = Charging contactor
NC = Controller error message
- open with fault in drive (servo error)
- closed with E-stop

RF
RK
RL
S1
S2
S3
S4
S5
T1

= Control drive enable signal
= DC bus dynamic brake resistor
= Charging resistor
= E-stop
= End position of axis
= Safety door
= Power Off
= Power on, cancel DC bus dyn. brake
=Matching transformer, dropped with 3 x AC 220 V

ATTENTION: With the release of K2 do not switch contactor back on for 0.5s.
K2 must be prevented from dropping out and picking up due to the successive opening and closing of S2 or K3, as
otherwise K2 could be damaged. Contactor K2 may only be switched back, once switched off, with a defined
command (e.g., S5).
SSDDS2

Fig. 8-2: Control circuit with indirect power on of power section via charging resistor with DDS drive controllers

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Powering up the power sections via charging resistors

8-2

DDS02.1/03.1

9

Condition at delivery
The merchandise is packed into cartons at the time of delivery. In the case of individual or mixed orders (several different units), all units are pakked in individual one-way cartons. Accessories are in a separate carton.
All individual cartons are combined in one large transport container at the
time of delivery (on a carton or pallet).
If several units are delivered, then return-packaging can be used.
There is an envelope containing two delivery slips on the transport container. There are no other papers, unless specifically requested.
Packaging can be opened without causing damage by simply separating
the glued strips!

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Condition at delivery 9-1

DDS02.1/03.1

10

Identifying the merchandise
In the case of a mixed order, the transport container contains the individually packaged controllers and accessories. In the case of a multiple
order of the same units, the accessories may be placed in a separate
transport container.
There is a barcode sticker on the DDS package. It identifies the contents
in type and order processing.
Type designation

GmbH Lohr/Main
Made in W-Germany

Unit serial number

DDS02.1-W050-DA0
1-00-FW
247204-02032
136672
0001
REXROTH MECMAN

Position number
on delivery slip
Consignment no.
Customer co.
Coded
type designation
Position no.
on del. slip
Consignment no.
Serial number of the
unit

247204-02032
TSDDS2G

Fig. 10-1: Barcode sticker on the DDS packaging (example)

If several identical units are in one package, then the serial numbers of all
the units contained therein are under the barcode sticker (only in the case
of return packaging).
There is a rating plate on the front of the DDS.

Type
designation
INDRAMAT
part no.

Coded
serial
no.

DDS 02.1-W100-D
247199-02094
247199

SN 247199-02094
Serial no.

Shipping
date
week/
year

K16/93

A05
Internal i.d.
TSDDS2X

Fig. 10-2: Rating plate of the basic DDS unit

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Identifying the merchandise

10-1

DDS02.1/03.1

Accessories

The accessories are packaged in bags. The order designation is written
on the bag. There is a slip in the bag which lists order number and the
accessory parts. In the case of ready-made cables, the order number is
affixed to the cable, any other types of cables have the cable number
printed on them.
Page 1

Page 2

Designation

No.

S1 - DDS 2

1

Part

D-subm. conn., 15 pin female
8
15

1

1
9

D-subm. connector, 15 pin

220623

8
15

1

250 811

223008

9

4

for configuration of
units:

Screw

221657

2

15 pin housing

221661

DA01-00
DA02-00
1

1

Page 3

241647

10 pin plugin clamp
2

3

4

5

6

7

8

9

10

Page 4

Date: 04.11.92
File: S1-DDS2
Part no. BPZ:

Deliver slip for S1-DDS2
No.:109-0852-4206-00

BPZDDS3

Fig. 10-3: Examples of a delivery slip

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Identifying the merchandise

10-2

DDS02.1/03.1

11

Storage and transportation
The controllers must be stored in a dry, dust and shock free environment
within a permissible temperature range of -30 to +85 degrees Celsius.
Use shock-damping supports during transport if necessary!
Transport notes found on the packaging:

Achtung
Hochwertige Elektronik
Attention
Fragile Electronics
Vor Nässe schützen
Nicht belasten
Do not apply load
Do not drop

Nicht werfen
Nicht kanten
Do not tip
Keep dry
TSDDS2Y

Fig. 11-1: Safety guidelines for transportation

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Storage and transportation 11-1

DDS02.1/03.1

12

M

Index

Motor feedback 6-12
Motor power cable 6-4
Motor temperature monitoring 6-7

A

Mounting conditions 5-1
Mounting panel 5-5

Accessories 7-1, 10-2
mechanical 7-9

Accessories kit

P

M2-F 7-9

Peak current 4-1

SH-FL 7-9

Plugin module 3-10

Ambient conditions 4-4

Power dissipation 5-5
DDS02.1-A... 4-6
DDS02.1-F... 4-7

B

DDS02.1-W... 4-5

Blower 5-5

DDS03.1-W... 4-8

Blower unit 6-14, 7-8
Bus connection 6-8

C

R
Rating plate basic unit 10-1
Ready to operate contact Bb 6-9

Cable length 6-4

Resolver feedback 6-12

Cable lengths 6-12

RS232 6-11

Condense water 5-13
Configuration rating plate 3-12
Configurations 3-13

S

Configured drive controllers 3-1

Software module 3-7

Connector kit 7-1

Starting lockout 6-10

Continuous current 4-1

Supply units 1-2, 8-1

D

T

DC bus voltage 6-7

Technical data 4-1

Diagnostic outputs 6-9

Terminal diagram 6-16

Digital Servo Feedback 6-12

Transportation 11-1

Dimensional sheet
DDS02.1-A... 5-6
DDS02.1-W... 5-4
DDS03.1-W... 5-12
M2-F 5-11
SH-FL 5-11

Drive controller
basic unit 3-4

Drive controller components 3-2
Drive controller cooling modes 3-5
Drive controller type codes 3-3, 3-6

E
EMC 5-13
Environmental conditions 4-4

F
Feedback connection 6-13
Firmware 3-7, 3-9

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Index 12-1

DDS02.1/03.1

Customer Service Location Directory
Germany
Central sales region

Sales region east

Sales region west

Sales region north

INDRAMAT GmbH
D-97816 Lohr am Main
Bgm.-Dr.-Nebel-Str. 2

INDRAMAT GmbH
D-09120 Chemnitz
Beckerstraße 31

INDRAMAT GmbH
D-40849 Ratingen
Hansastraße 25

INDRAMAT GmbH
D-22085 Hamburg
Fährhausstraße 11

Telefon: 09352/40-0
Telefax: 09352/40-4885

Telefon: 0371/3555-0
Telefax: 0371/3555-230

Telefon: 02102/4318-0
Telefax: 02102/41315

Telefon: 040/227126-16
Telefax: 040/227126-15

Sales region south

Sales region southwest

INDRAMAT Service-Hotline

INDRAMAT GmbH
D-80339 München
Ridlerstraße 75

INDRAMAT GmbH
D-71229 Leonberg
Böblinger Straße 25

INDRAMAT GmbH
Telefon: D-0172/660 040 6

Telefon: 089/540138-30
Telefax: 089/540138-10

Telefon: 07152/972-6
Telefax: 07152/972-727

-oderTelefon: D-0171/333 882 6

Kundenbetreuungsstellen in Deutschland

Europe
Austria

Austria

Belgium

Denmark

G.L.Rexroth Ges.m.b.H.
Geschäftsbereich INDRAMAT
A-1140 Wien
Hägelingasse 3

G.L.Rexroth Ges.m.b.H.
Geschäftsbereich INDRAMAT
A-4061 Pasching
Randlstraße 14

Mannesmann Rexroth N.V.-S.A.
Geschäftsbereich INDRAMAT
B-1740 Ternat
Industrielaan 8

BEC Elektronik AS
DK-8900 Randers
Zinkvej 6

Telefon: 1/9852540-400
Telefax:1/9852540-93

Telefon: 07229/4401-36
Telefax: 07229/4401-80

Telefon: 02/5823180
Telefax: 02/5824310

England

Finnland

France

France

Mannesmann Rexroth Ltd.
INDRAMAT Division
Cirencester, Glos GL7 1YG
4 Esland Place, Love Lane

Rexroth Mecman OY
SF-01720 Vantaa
Riihimiehentie 3

Rexroth - Sigma S.A.
Division INDRAMAT
F-92632 Gennevilliers Cedex
Parc des Barbanniers 4,
Place du Village

Rexroth - Sigma S.A.
Division INDRAMAT
F-69634 Venissieux - Cx
91, Bd 1 Joliot Curie

Telefon: 01285/658671
Telefax: 01285/654991

Telefon: 0/848511
Telefax: 0/846387

Telefon: 1/41475430
Telefax: 1/47946941

Telefon: 086/447866
Telefax: 086/447160

Telefon: 78785256
Telefax: 78785231

France

Italy

Italy

Netherlands

Rexroth - Sigma S.A.
Division INDRAMAT
F-31100 Toulouse
270, Avenue de lardenne

Rexroth S.p.A.
Divisione INDRAMAT
I-20063 Cernusco S/N.MI
Via G. Di Vittoria, 1

Rexroth S.p.A. Divisione
INDRAMAT
Via Borgomanero, 11
I-10145 Torino

Hydraudyne Hydrauliek B.V.
Kruisbroeksestraat 1a
P.O. Box 32
NL-5280 AA Boxtel

Telefon: 61499519
Telefax: 61310041

Telefon: 02/92365-270
Telefax: 02/92108069

Telefon: 011/7712230
Telefax: 011/7710190

Telefon: 04116/51951
Telefax: 04116/51483

Spain

Spain

Sweden

Switzerland

Rexroth S.A.
Centro Industrial Santiago
Obradors s/n
E-08130 Santa Perpetua de Mogoda (Barcelona)

Goimendi S.A.
División Indramat
Jolastokieta (Herrera)
Apartado 11 37
San Sebastion, 20017

AB Rexroth Mecman
INDRAMAT Division
Varuvägen 7
S-125 81 Stockholm

Rexroth SA
Département INDRAMAT
Chemin de l`Ecole 6
CH-1036 Sullens

Telefon: 03/718 68 51
Telex: 591 81
Telefax: 03/718 98 62

Telefon: 043/40 01 63
Telex: 361 72
Telefax: 043/39 93 95

Telefon: 08/727 92 00
Telefax: 08/64 73 277

Telefon: 021/731 43 77
Telefax: 021/731 46 78

Switzerland

Russia

Rexroth AG
Geeschäftsbereich INDRAMAT
Gewerbestraße 3
CH-8500 Frauenfeld

Tschudnenko E.B.
Arsenia 22
153000 Ivanovo
Rußland

Telefon: 052/720 21 00
Telefax: 052/720 21 11

Telefon: 093/22 39 633

European customer service locations without Germany

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

DDS02.1/03.1

Outside of Europe
Argentina

Argentina

Australia

Brazil

Mannesmann Rexroth S.A.I.C.
Division INDRAMAT
Acassusso 48 41/7
1605 Munro (Buenos Aires)
Argentina

Nakase
Asesoramiento Tecnico
Diaz Velez 2929
1636 Olivos
(Provincia de Buenos Aires)
Argentina
Argentina

Australian Industrial Machenery
Services Pty. Ltd.
Unit 3/45 Horne ST
Campbellfield VIC 2061
Australia

Mannesmann Rexroth Automação
Ltda.
Divisão INDRAMAT
Rua Georg Rexroth, 609
Vila Padre Anchieta
BR-09.951-250 Diadema-SP
Caixa Postal 377
BR-09.901-970 Diadema-SP

Telefon: 01/756 01 40
01/756 02 40
Telex: 262 66 rexro ar
Telefax: 01/756 01 36

Telefon: 03/93 59 0228
Telefax: 03/93 59 02886

Telefon 01/790 52 30

Telefon: 011/745 90 65
011/745 90 70
Telefax: 011/745 90 50

Canada

China

China

China

Basic Technologies Corporation
Burlington Division
3426 Mainway Drive
Burlington, Ontario
Canada L7M 1A8

Rexroth (China) Ldt.
Shanghai Office
Room 206
Shanghai Intern. Trade Centre
2200 Yanan Xi Lu
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P.R. China

Rexroth (China) Ldt.
Shanghai Parts & Service Centre
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Minhang District
Shanghai 201 103
P.R. China

Rexroth (China) Ldt.
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1, Jianguomenwai Avenue
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P.R. China

Telefon: 905/335-55 11
Telefax: 905/335-41 84

Telefon: 021/627 55 333
Telefax: 021/627 55 666

Telefon: 021/622 00 058
Telefax: 021/622 00 068

Telefon: 010/50 50 380
Telefax: 010/50 50 379

China

Honkong

India

Japan

Rexroth (China) Ldt.
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Sha He Kou District
Dalian 116 023
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Rexroth (China) Ldt.
19 Cheung Shun Street
1st Floor, Cheung Sha Wan,
Kowloon, Honkong

Mannesmann Rexroth (India) Ltd.
INDRAMAT Division
Plot. 96, Phase III
Peenya Industrial Area
Bangalore - 560058

Rexroth Co., Ltd.
INDRAMAT Division
I.R. Building
Nakamachidai 4-26-44
Tsuzuki-ku, Yokohama 226
Japan

Telefon: 0411/46 78 930
Telefax: 0411/46 78 932

Telefon: 741 13 51/-54 und
741 14 30
Telex: 3346 17 GL REX HX
Telefax: 786 40 19
786 07 33

Telefon: 80/839 21 01
80/839 73 74
Telex: 845 5028 RexB
Telefax: 80/839 43 45

Korea

Korea

Mexico

Rexroth-Seki Co Ltd.
1500-12 Da-Dae-Dong
Saha-Gu, Pusan, 604-050

Seo Chang Corporation Ltd.
Room 903, Jeail Building
44-35 Yoido-Dong
Youngdeungpo-Ku
Seoul, Korea

Motorización y
Diseño de Controles, S.A. de C.V.
Av. Dr. Gustavo Baz No. 288
Col. Parque Industrial la Ioma
Apartado Postal No. 318
54060 Tlalnepantla
Estado de Mexico

Telefon: 051/264 90 01
Telefax: 051/264 90 10

Telefon: 02/780-82 07 ~9
Telefax: 02/784-54 08

Telefon: 5/397 86 44
Telefax: 5/398 98 88
USA

USA

Rexroth Corporation
INDRAMAT Division
5150 Prairie Stone Parkway
Hoffman Estates, Illinois 60192

Rexroth Corporation
INDRAMAT Division
2110 Austin Avenue
Rochester Hills, Michigan 48309

Telefon: 847/645-36 00
Telefax: 857/645-62 01

Telefon: 810/853-82 90
Telefax: 810/853-82 90

Customer service locations outside of Europe

DOK-DIAX02-DDS02.1/3.1-PRJ1-EN-E1,44 • 04.97

Telefon: 045/942-72 10
Telefax: 045/942-03 41

Indramat


Indramat Bosch.rar > Zasialcz montażowa.pdf

engineering

mannesmann
Rexroth

TVD 1.3
Power Supply Module for Direct Connection to
3 x AC 380...480V Mains Supply
Applications Manual
DOK-POWER*-TVD*1.3****-ANW1-EN-P

271434

Indramat

About this documentation

Title

Type of documentation
Document code
Internal file reference

Reference

The purpose of the
documentation

Editing sequence

TVD 1.3
Supply Module for Direct Connetion to 3 x AC 380...480V Mains Supply
Applicationsbeschreibung
DOK-POWER*-TVD*1.3****-ANW1-EN-E1,44
• Mappe 6
• TVD13-AN.pdf
• 209-0049-4309-01
This electronic document is based on the hardcopy document with document
desig.: DOK-POWER*-TVD*1.3****-ANW1-EN-P • 11.96
This document serves to:
• define the applications range
• support the electrical construction of the machine
• support the mechanical construction of the cabinet
• mounting and installation
• selecting the additional components
• help with the clearing of faults

Doc. designations of previous editions

Status

Comments

209-0049-4309-00 DE/07.96

JUL./96 Preliminary without print

DOK-POWER*-TVD*1.3****-ANW1-EN-P

NOV./96 2nd edition

DOK-POWER*-TVD*1.3****-ANW1-EN-E1,44

Copyright

JUL./96 1st edition

DOK-POWER*-TVD*1.3****-ANW1-EN-P

Feb./97

1st edition E-Dok

© INDRAMAT GmbH, 1996
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 for the payment of damages. All rights are reserved in the event of the
grant of a patent or the registration of a utility model or design (DIN 34-1).
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.

Validity

Published by

All rights are reserved with respect to the content of this documentation and
the availability of the product.
INDRAMAT GmbH • Bgm.-Dr.-Nebel-Straße 2 • D-97816 Lohr
Telefon 0 93 52 / 40-0 • Tx 689421 • Fax 0 93 52 / 40-48 85
Dept. ENA (DE, FS)

• DOK-POWER*-TVD*1.3****-ANW1-EN-E1,44 • 02.97

2

Table of Contents

Table of Contents
1.

Construction of INDRAMAT Modular A.C. Drive System

7

1.1.

Main functions of the TVD 1.3 .......................................................... 8

2.

Range of Applications

2.1

Functional power features of the TVD 1.3 .....................................10

2.2.

Power ratings of the TVD 1.3 ......................................................... 11

2.3.

Overload Capabilities of the TVD 1.3 ............................................. 11

2.4.

Technical Data - TVD 1.3 ...............................................................12

2.5.

Ambient Conditions ........................................................................13

3.

Electrical Connections – Installation Guidelines

3.1.

Interconnect diagram TVD 1.3 with NAM 1.3.................................15

3.2.

TVD 1.3 interconnect diagram with individual,
additional components ................................................................... 16

3.3

Mains connection devices ..............................................................17

3.4.

Mains connection to power circuits ................................................ 19

3.5.

Fuse protection for direct mains connection ..................................21

3.6.

Mains supply earthing requirements ..............................................21

3.7.

Commutation choke .......................................................................23

3.8.

DC bus circuit .................................................................................23

3.9.

DC bus smoothing choke ...............................................................24

9

14

3.10. Additional DC bus capacitance ......................................................24
3.11. Bridge circuit capacitance ..............................................................24
3.12. Additional bleeder module TBM .....................................................25
3.13. External bleeder resistor ................................................................26
3.14. Supply to electronics and blower ...................................................27
3.15. Electronics supply buffer capacitance ............................................28
3.16. Electronics supply and signal exchange
connections .................................................................................... 29
3.17. Residual current operated devices ................................................ 30
3.18. Control cabinet testing ................................................................... 31
3.19. Mounting the TVD 1.3 into the control cabinet ............................... 31
• DOK-POWER*-TVD*1.3****-ANW1-EN-E1,44 • 02.97

3

Table of Contents

3.20. Heat loss inside the control cabinet ...............................................33
3.21. Safety clearance inside the control cabinet ...................................33
3.22. Front view of the TVD 1.3 ..............................................................34

4.

TVD 1.3 Interconnections

35

4.1.

Optional Control Possibilities ......................................................... 35

4.2.

TVD interconnect with DC bus dynamic braking ...........................36

4.3.

TVD interconnect with E-stop relay with DC bus
dynamic braking .............................................................................38

4.4.

TVD interconnect without DC bus dynamic braking ...................... 40

4.5.

TVD interconnect for a position-controlled braking of the drives ... 42

5.

Terminal Descriptions

5.1.

DC bus short-circuiting ................................................................... 44

5.2.

Power off ........................................................................................44

5.3.

Power on ........................................................................................44

5.4.

Stopping the drives in an E-stop or a power failure ....................... 45

5.5.

Signal Voltages ..............................................................................46

5.6.

" Ready " status ................................................................................46

5.7.

Power OK .......................................................................................48

5.8.

Regenerated power too high .......................................................... 48

5.9.

Temperature Pre-Warning ..............................................................49

44

5.10. Mains contactor de-energized ........................................................ 49
5.11. Mains contactor energized .............................................................49

6.

Troubleshooting

6.1.

Localizing the fault .........................................................................50

6.2.

Diagnostic display .......................................................................... 53

6.3.

Definition of the displays ................................................................54

6.4.

Rating plate data ............................................................................57

7.

Dimensional data

7.1.

Dimension sheet TDV 1.3 power supply mdule .............................58

• DOK-POWER*-TVD*1.3****-ANW1-EN-E1,44 • 02.97

50

58

4

Table of Contents

7.2.

Dimension sheet NAM 1.3 power adapting module ....................... 59

7.3.

Dimension sheet CZ 1.2-01-7 bus voltage capacitor ....................60

7.4.

Dimension sheet KD 23/26 commutating chokes ..........................61

7.5.

Dimension sheet DC bus smoothing choke
GLD 16/17 ......................................................................................61

7.6.

Dimension sheet CZ 1.02 auxiliary capacitance ............................62

7.7.

Dimension sheet TCM 1.1 aux. capacitance mod. ........................ 62

7.8.

Dimension sheet TBM aux. bleeder module ..................................63

7.9.

DST Autotransformers with a secondar or output voltage of
380...460 V .....................................................................................64

8.

Order information

8.1.

Type codes TVD .............................................................................65

8.2.

Available supply module types of the TVD 1.3 and accessories ... 65

8.3.

Overview of electrical connecting accessories .............................. 66

8.4.

Overview of 16-pin bus cable for NAM 1.3 ....................................66

8.5.

Item list of mains supply with TVD 1.3 ...........................................67

9.

Index

• DOK-POWER*-TVD*1.3****-ANW1-EN-E1,44 • 02.97

65

68

5

ty
p e
m ag
E p

• DOK-POWER*-TVD*1.3****-ANW1-EN-E1,44 • 02.97

6

1. Construction of the Modular AC Drive System

1.

Construction of INDRAMAT Modular
A.C. Drive System

The modular AC drive system from INDRAMAT is made up of
• auxilary units
• supply modules and
• drive modules.
These can be combined depending upon the power and functionalities
required.
Power Supply

Mains
3xAC 380 ... 460V
50 ... 60Hz
L1 L2 L3

auxilary units
commutating
reactor
DC bus
smoothing
reactor
buffer capacitor

Drive

Power Supply Module TVD 1.3

Drive module
Programming module

Signal
voltages
internal power
contactor

control, monitoring,
diagnoses

Bleeder

internal DC bus
short-circuit

n
act
M
G
feed motor

TVD/AntriebAufbau

Fig. 1.1:

The TVD 1.3 supply module as part of the INDRAMAT AC drive system

• DOK-POWER*-TVD*1.3****-ANW1-EN-E1,44 • 02.97

7

1. Construction of the Modular AC Drive System

1.1. Main functions of the TVD 1.3
Power supply to the
drives

The high-voltage link rectifies the three-phase mains AC and provides a
regulated DC bus circuit voltage for the power feed to the drives. A buffer
capacitor takes care of any necessary smoothing.
When the drives are in generator mode, the regenerated power is absorbed
by the bleeder resistor and transformed into heat.
The drives can be disconnected from the mains by the TVD's internal power
contactor.

Supply to the
electronics

The TVD 1.3 provides the +24VL and +/-15VM for all connected drive
modules.
In the event of a power failure, the signal voltages are supplied from the DC
bus circuit. Therefore, as the drives operate as a generator, the electronics of
the drives remain functional.

Drive system
monitoring

The TVD 1.3 is equipped with extensive monitoring functions. These
communicate with the drive modules via the wire ribbon cable.
The Bb1 contact is critical to the ready state of the drive system. The power
contactor cannot be energized until the Bb1 contact is closed.

Bleeder

DC bus s.c.

320 V DC
as power
source of
drives

1U1
DC
DC

1V1
1W1
K1

~

Power source and
monitoring of drives

=

Drives ready
AufbauTVR3

Fig. 1.2:

&

Bb1

Power supply ready

The basic construction of the TVD 1.3

• DOK-POWER*-TVD*1.3****-ANW1-EN-E1,44 • 02.97

8

2. Range of Applications

2.

Range of Applications

INDRAMAT drives up to a continuous mechanical output of 12kW can be run
from the TVD line of supply modules.
The TVD 1.3 operates without mains regeneration.
Drives with mains regeneration for regenerated power exceeding 2 kW are,
however, available.

Mains

L1
L2
L3

Input to
network

Supply module

15 kW

Drive module

≤ 1 kW*)

*) By combining with auxiliary
bleeder 1.5 or 2.0 kW
TVDLeistbereich

Fig. 2.1:

P
m

P
m

Continuous mechanical
power up to 12 kW

Power range of the applications of the TVD 1.3

• DOK-POWER*-TVD*1.3****-ANW1-EN-E1,44 • 02.97

9

2. Range of Applications

2.1

Functional power features of the TVD 1.3

• Connected load
The TVD 1.3 can be operated with power systems of 3 x AC 380..480V,
50...60Hz without a transformer. Additional auxilary units are offered (NAM
1.3..) which suppress reactions on the power system.
• Power shutdowns by internal contactors
The contactor to shut down power to the power system of the drives is an
integrated component of the TVD 1.3.
• Internal DC bus dynamic braking
Motors with permanent magnetic fields can be braked to a standstill by the
DC bus dynamic brake in the event of fault conditions in the drive electronics.
• How the drive system responds to a power failure
can be programmed by inserting an external jumper:
– without a jumper, the drives brake at maximum torque
– with a jumper, a signal via a potential-free contact is transmitted to the NC
control unit which can then brake the drives controlled to a standstill.
Costly tools and workpieces are thus protected against damage.
• Regulated DC bus voltage
Drive dynamics maintained with mains undervoltage.
• Charging current limit of the DC bus capacitors
The inrush current does not have to be taken into consideration when
selecting the switching devices of the power system. This extends the service
life of these devices.
• Extreme load capabilities of the control voltage
Up to ten drive modules can generally mounted to one supply module.
• Easy to service
The signal leads are connected via plug-in screw clamps.
• Two different power stages available
The supply module TVD 1.3 is available with a continuous DC bus power of
7.5 kW or 15 kW. This means that the power supply can be optimally matched
to the requirements of the respective application.
• Overload capabilities of the TVD 1.3
The TVD 1.3 can overloaded for a short duration for the purpose of
accelerating feed and main drives.
The maximum possible acceleration power, as relates to the duration of
acceleration, is outlined in the section " Overload Capabilities of the TVD 1.3 " .
The values found there must be taken into account during project planning
and may not be exceeded.
• UL Registered
The device is made according the UL-Standard.

• DOK-POWER*-TVD*1.3****-ANW1-EN-E1,44 • 02.97

10

2. Range of Applications

2.2. Power ratings of the TVD 1.3
The TVD 1.3 is available with a DC bus continuous power of 7.5 kW and 15
kW. It can be combined with an auxiliary bleeder module. This means that the
power supply can be optimally matched to the requirements of the respective
application.
(1)

(2)

(3)

(4)

(5)

(6)

(7)

PDC
kW

PKB-3
kW

PKB-03
kW

P BD
kW

PBM
kW

Wmax
kWs

Pm
kW

7,5
7,5
15
15

15
15
30
30

22,5
22,5
45
45

0.5
1.5
1.0
2.0

20
60
40
80

30
130
60
160

6
6
12
12

(8)

(9)

Power supply components

PmKB-3 P mKB-03 TVD 1.3
kW
kW
12
12
24
24

18
18
36
36

-08-03
-08-03
-15-03
-15-03

Power conn.
module

Auxiliary bleeder
module

NAM 1.3-08
NAM 1.3-08
NAM 1.3-15
NAM 1.3-15

--------------------TBM 1.2-40-W1
--------------------TBM 1.2-40-W1

(1) PDC

= continuous DC bus power

(6) Wmax

= maximum regenerated energy

(2) PKB-3

= DC bus short-term power for
3s (accel. of spindle drive)

(7) Pm

= mechanical output for ON time of
& gt; 10s

(3) PKB-03

= DC bus peak power for
0.3s (accel. feed drives)

(8) P mKB-3 = mechanical short-term output for
3s (accel. of spindle drive)

(4) PBD

= Bleeder continuous power

(9) PmKB-03 = mechanical peak output for
0.3s (accel. feed drives)

(5) PBM

= Bleeder peak power
Fig. 2.2:

Power ratings in the TVD 1.3

2.3. Overload Capabilities of the TVD 1.3
The TVD 1.3 can be overloaded for a short duration for the purpose of
accelerating feed and spindle drives.
The maximum acceleration ratings must be taken into account
during project planning and may not be exceeded!

300
Peak power for 0.3 s to
accel feed drives

200

Power limit
Short-term operating power for 3 s
to accelerate the spindle drives

Load P/%

100

Continuous power for ON time
exceeding 10 s

0.3

10

3
ON time t/s

TVRBelastungsdiagr

Fig. 2.3: Load diagram - TVD 1.3
• DOK-POWER*-TVD*1.3****-ANW1-EN-E1,44 • 02.97

11

2. Range of Applications

2.4. Technical Data - TVD 1.3
Designation

Symbol Unit

TVD 1.3-15-3

TVD 1.3-08-3

Power section
Input voltage

U(ACN)

Frequency

f(N)

DC bus voltage

U(DC)

(V)

3 x 380 ... 480 (± 10%)

(Hz)

50 ...60

(V)

320 (± 5%)

Continuous DC bus power

P(DC)

(kW)

15

7.5

Peak DC bus power (for 0.3 s)

P(KB-03)

(kW)

45

22.5

Bleeder continuous power

P(BD)

(kW)

1

0.5

Bleeder peak power

P(BM)

(kW)

40

20

Maximum regenerated energy

W(max)

(kWs)

60

30

Power dissipation with maximum power
(without bleeder loss)

P(v)

330

180

Basic loss

(W)
(W)

75

Power loss per kW continuous
DC bus power

17

Weight

m

11,2

(kg)

14
10.5

Electronics supply
Input voltage

U(AC)

Frequency

f(N)

(Hz)

(V)

3 x 380 ... 480 (±10%)
50 ... 60

Incomming power

S(el)

(VA)

300

+ 24V load voltage

U(L)

(V)

22 ... 26

+ 24VL continuous current

I(UL)

Control voltage output

(A)

7.5

(%)

+ 24VL ripple

2

± 15V measuring voltage

U(M)

(V)

14.9 ... 15.1

+ 15VM continuous current

I(+UM)

(A)

2.5

- 15VM continuous current

I(-UM)

(A)

1.5 (2.0)

(%)

0.1

± 15VM ripple

1)

Ambient conditions
Permissible ambient temperature
with rated data

T(um)

(°C)

+5 ... +45

Maximum permissible ambient temperature
with derated data

T(umr)

(°C)

55

Storage and transport temperatures

T(L)

(°C)

-30 ... +85

Installation elevation with derating

max. 1000 meters above sea level

Permissible relative humidity

max. 95%

Permissible absolute humidity

25g water / m3 Luft

Protection category

IP 10 per DIN 40 050

Contamination level

non-conductive dirt, no condensate

Suitable auxilary units

1)

NAM 1.3-15

NAM 1.3-08

The -15VM can be loaded with a maximum of 2 A.
The load of + 15VM and - 15VM combined may not exceed 4 A.

Fig. 2.4: Technical data of supply module TVD 1.3

• DOK-POWER*-TVD*1.3****-ANW1-EN-E1,44 • 02.97

12

2. Range of Applications

2.5. Ambient Conditions
The DC bus power and control voltage loads listed in the data sheets apply to
an ambient temperature of +5 to +45oC. The maximum permissible ambient
temperature may equal +55 o C. The power data, in this case, derate as per the
diagram below.

100

Derating factor in %

Increased ambient
temperatures

80
60
40
20
0
0

10

20

30

40

50

60

Ambient temperature ϑ in °C

DGTemp

Fig. 2.5: The derated power data with increased ambient temperatures

The power data is derated as per the following diagrams in the case of
installation of 1000 meters above sea level.

Derating factor in %

Installation elevations
exceeding 1000 m

100
80
60
40
20
0
0

1000

DGHöheDDS3

2000

3000

4000

5000

Installation elevation in m

Fig. 2.6: Power data derated for installation elevations exceeding 1000 meters

• DOK-POWER*-TVD*1.3****-ANW1-EN-E1,44 • 02.97

13

3. Electrical Connections

3.

Electrical Connections – Installation
Guidelines

The interconnection diagram found in this documentation is a
recommendation of the equipment manufacturer.
The wiring diagram of the machine builder should be used for
installation.

• DOK-POWER*-TVD*1.3****-ANW1-EN-E1,44 • 02.97

14

• DOK-POWER*-TVD*1.3****-ANW1-EN-E1,44 • 02.97

temp. prewarning

bleeder prewarning

power voltage ok

ready

acknowledge power on

acknowledge power off

max. 2 A

max. 100 mA

NC regulated braking

ON

OFF

ZKS

1
2
3
4
5
6
7
8

X4

X5
K1
1
2
K1
3
4

1
NCB
2
3 +15VM
4 0VM
5 -15VM
6
shield
7 +24V
8 0VL

X2
1 ZKS
2 ZKS
3 OFF
4 OFF
5 ON
6 ON
X3

13,14

0VL

TVW

BVW

UD

Bb1

2U1
2V1
2W1
K1

X7

X7

U2 V2 W2

U1 V1 W1

1U1
1V1
1W1

11,12

X7

N

P

X8

R1

C1

+ -

EB

BR1

Supply module for direct connection of the
mains
- with built-in bleeder
- with regulated DC bus

TVD 1.3

electronics
supply

power
supply

X8

1L+ 2L+
X7

NAM 1.3

P

X1

N

+24V

1L+

from TVD connector X1:
16-pin bus connection
for blower supply

2L+

Q1

RB1
RB2

3xAC (380 - 480) V
(50 - 60) Hz

EPU+
EPU -

Fig. 3.1:
IB

PE
L3
L2
L1

X7

X9

L+

L-

PE

1
UD
2
BB
3, 4
+15V
5, 6, 7, 8
0VM
9, 10
-15V
11, 12
+24V
13, 14
0VL
15
UESS
16
shield
X1

X 12

Circuit diagram for a TVD 1.3 with mains connection module NAM 1.3
with 380 ... 480V supply connection and internal electronics - internal power switch

L- L+

R2

Electronics
power
source,
signal
exchange,
16-pin
bus
connection

1

2

+24V 0V

X16

TBM

Power
supply
for AC
drives
and/or
main
spindle
drives

for TBM with
DC 24V blower
power

DC 300V
conductor rails

X7/EB

EB

X15

Options
R1 - Bleeder
can be mounted externally
R2 - auxiliary bleeder module TBM
C1 - additional electronics backup
C2 - additional power buffer

NAM - power connection module
BR1 - bridge for switching bleeder

- +

C2

central ground point
for all drive modules

3. Electrical Connections

3.1. Interconnect diagram TVD 1.3 with NAM 1.3

TVD12/NAM12Anschlpl

Interconnect diagram -TVD 1.3 supply module with NAM 1.3

15

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temp. prewarning

bleeder prewarning

power voltage ok

ready

acknowledge power on

acknowledge power off

max. 2 A

max. 100 mA

NC controlled braking

ON

OFF

ZKS

1
2
3
4
5
6
7
8

X4

X5
K1
1
2
K1
3
4

TVW

BVW

UD

Bb1

2U1
2V1
2W1

1
NCB
2
3 +15VM
4 0VM
5 -15VM
6
shield
7 +24V
8 0VL

X2
1 ZKS
2 ZKS
3 OFF
4 OFF
5 ON
6 ON
X3

U2 V2 W2

K1

X7

N

P

P

C1

+ -

TVD 1.3

electronics
supply

power
supply

X8

2

1

R1

EB

BR1

X7

Power supply module for direct connection
- with built-in bleeder
- with regulated DC bus

N

L1

1L+

C3

2L+

U1 V1 W1

RB1
RB2

L2

1U1
1V1
1W1

Q1

EPU+
EPU -

Fig. 3.2:
IB

3xAC (380 - 480) V
(50 - 60) Hz

PE
L3
L2
L1

X9

L+

L-

PE

1
UD
2
BB
3, 4
+15V
5, 6, 7, 8
0VM
9, 10
-15V
11, 12
+24V
13, 14
0VL
15
UESS
16
shield
X1

X 12

Terminal diagram for Supply Module TVD 1.3 with Individual Components
with 380 ... 480V mains connection for power and electronics - internal power switch

L- L+

R2

Electronics
power
supply,
signal
exchange,
16-pin
bus
connection

1

2

+24V 0V

X16

TBM

drives

spindle

main

and/or

drives

AC

for

supply

Power

for TBM with
DC 24V blower
power source

DC 300V
conductor rails

X7/EB

EB

X15

Options
R1 - bleeder, ext. mounting
R2 - auxiliary bleeder module TBM
C1 - additional electronics backup
C2 - additional power backup

BR1 - bridge for switching
the bleeder
C3 - Buffer capacitance
L1
- DC bus smoothing reactor
L2
- commutating reactor

- +

C2

central grounding point
for all drive modules

3. Electrical Connections

3.2. TVD 1.3 interconnect diagram with individual,
additional components

TVD/KompAnschlpl

Interconnect diagram of TVD 1.3 supply module with individual additonal
components

16

3. Electrical Connections

3.3

Mains connection devices

Due to regulated current consumption, the TVD 1.3 supply module offers the
lowest possible mains loading without reactive current.
Current regulators in switched-mode power supply system cause mains
system perturbations, the level of which depend on existing system conditions,
i.e., short-circuit power or mains inductance, at the installation site.
To eliminate mains perturbance, the TVD 1.3 supply module is operated from
the mains supply via auxilary devices.
The auxilary devices are available as either compact mains connection
module NAM 1.3 or in the form of individual components.

TVD 1.3 with adapter
module NAM 1.3

All the necessary components like the commutation choke, storage capacitor
and DC bus smoothing choke, are in the mains connection module. This
keeps installation work to a minimum.
Available device combinations:
Supply module

Mains connection module

TVD 1.3-08-3

NAM 1.3-08

TVD 1.3-15-3

NAM 1.3-15

stranded,
max.
2 m long
3)

PE

NAM 1.3- . . 2L+

1)

1L+
N

X12
X7/2L+
X7/1L+

2)

P

X8/N
X8/P

2)

L2

U1

U2

V1

V2

X7/1V1

W1

L1

TVD 1.3

W2

X7/1W1

L3

X7/1U1

L+

L-

16-pin bus cable
(NAM blower power supply)
IN 175/155
2
1) min. lead cross section .……………………………….....4 mm with TVD 1.3-08
2
min. lead cross section: .………………………………....16 mm with TVD 1.3-15
2
2) min. lead cross section: ………………………………....2.5 mm with TVD 1.3-08
2
min. lead cross section: ……………………………….......6 mm with TVD 1.3-15
3) ≥ 10 mm 2

Lead cross sections per EN 60204 - installation type B1 - correcting factors not taken into account
TVD / NAM 1.2

Fig. 3.3:

Connecting a TVD 1.3 supply module to the mains via adapter module NAM 1.3

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17

3. Electrical Connections

TVD 1.3 with separate
components

If modular installation is not possible due to space restrictions, then the supply
module can also be connected to the mains via separate components.
Required components:
Supply module

Commutation
choke

TVD 1.3-08-3

KD 26

CZ 1.2-01-7

GLD 16

TVD 1.3-15-3

KD 23

CZ 1.2-01-7

GLD 17

3)

GLD . .

PE

Buffer
DC bus
capacitor smoothing choke

X12
X7/2L+

1
1)

2

X7/1L+

stranded, max.
X8/N
2 m long
P

N

2)

TVD 1.3

X8/P
3)

CZ 1.2-01-7
KD . .
L1
L2
L3

PE

3)
3)

U1

PE
U2

V1

V2

W1

W2

X12

X7/1U1
2)

L+

X7/1V1
X7/1W1

stranded,
max.
15 m long

LTVD/CZ1201

1) min. lead cross section: .……………………………….....4 mm 2 with TVD 1.3-08
min. lead cross section: .………………………………....16 mm 2 with TVD 1.3-15
2) min. lead cross section: ………………………………....2.5 mm 2 wth TVD 1.3-08
min. lead cross section: ……………………………….......6 mm 2 with TVD 1.3-15
3) ≥ 10 mm 2

Lead cross sections per EN 60204 - installation type B1 - correcting factors not taken into account
Fig. 3.4:

Connecting a TVD 1.3 to the mains with individual components

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18

3. Electrical Connections

3.4. Mains connection to power circuits
Direct mains
connection

The TVD 1.3 can be connected to 3 x AC 380...480V,50...60Hz three-phase
AC mains supplies without the need for a transformer. See section 3.5 for fuse
protection information.
The power and electronic supply connections are strapped at the time of
delivery. Generally, a separate connection for the power source of the
electronics is not required.
Mains voltage:

3x AC 380 ... 480 V; ± 10 %

Mains frequency:

50 ... 60 Hz; ± 2 Hz

Voltage interrupt:

Maximum 8 ms at base load and 380 V mains
voltage without additional capacitance.
There must be a timespan of & gt; 1s between
sequential interrupts.

Voltage dips:

Supply system
requirements

20 % of the peak voltage for a maximum ofone
period, with 3 x 380V; a corresponding
percentage with higher voltages There must
be a timespan of & gt; 1s between sequential
interrupts.

3 x AC 380 … 480 V
L1
L2
L3
PE

mains fuses

NC control unit
PE-rail in
cabinet

U1

V1

W1
NC

≥10 mm 2
≥10 mm 2
U2

V2

≥10 mm 2

W2

2

1
X12 PE rail

1U1 1V1 1W1 1L+

2L+

RB1 RB2

X7 terminal block
2U1 2V1

2W1 EPU+ EPU-

IB

EB

TVD 1.3

drive
module

drive
module

1 Main lead stranded; max. 10 m long;
Lead cross sections per EN 60 204 (VDE 0113)
2 ≥ 10 mm 2

drive
module

TVDNetzanschluß

Lead cross sections per EN 60204 - installation type B1 - correcting factors not taken into account
Fig. 3.5:

Connecting block X7 with mutual power and electronics supply

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19

3. Electrical Connections

If the modular drives are to be operated in residential or light
industrial areas, then it may be necessary to mount an rf interference
filter to maintain the limit values for the emission of interference (rf
interference suppression).
Each drive module must be connected to the PE-rail of the TVD with a separate
ground lead.
The leakage current via the protective conductor is greater than 3.5
mA AC. A permanent connection is thus required for the TVD.

Mains connection via a
transformer

A transformer is needed if the mains voltage is less than 3 x 380V or greater
than 3 x 480V.
The mains inductance (leakage inductance) from transformers can vary
significantly depending on power and type of construction. Mains connection
components are therefore still needed even if transformers are used (see
section 3.3.).
Required transformer power:

S

STr
PDC
UN

=
=
=

TR

P × 3×UN
= DC
25,5

transformer power in VA
DC bus continuous power in W
transformer output voltage in V

stranded,
max.
2 m lang
3)

PE

NAM 1.3- . . 2L+

1)

1L+
N

3)

X12
X7/2L+

TVD 1.3

X7/1L+
2)

P

X8/N
X8/P

PE
2)

L1

U1

U2

L2

V1

V2

X7/1V1

L3

W1

W2

X7/1W1

X7/1U1

L+

L-

16-pin bus cable
(NAM blower power source)
IN 175/155

TVD/NAM12Trafo

1) min. lead cross section .……………………………….....4 mm2 with TVD 1.3-08
min. lead cross section: .………………………………....16 mm 2 with TVD 1.3-15
2) min. lead cross section: ………………………………....2,5 mm2 with TVD 1.3-08
min. lead cross section ……………………………….......6 mm 2 with TVD 1.3-15
3) ≥ 10 mm 2

Lead cross section per EN 60204 - installation type B1 - correcting factors not taken into account
Fig. 3.6:

Mains connection TVD 1.3 via a transformer

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20

3. Electrical Connections

3.5. Fuse protection for direct mains connection
Protection for the mains input to the power section of the TVD 1.3 for direct
connection to the mains can be effected by power circuit-breaker or with
fusible links, utilization category gL.

Maximum fusing

The fuse rating may not exceed 35 A.
The following recommendations are valid when circuit breakers are used for
direct connection to mains.
If fuses are used, then fuses with utilization category gL can be used. Semiconductor fuses are not required. Select the fuses in terms of the mains
current.

IN =
IN
PDC
UN

DC bus
contin.
power
7,5 kW
15 kW

PDC
UN • 25, 5

= mains current in A
= DC bus continuous power in W
= mains voltage in V

Connected Mains current
load
at
at380V
380V
480V
10 kVA
20 kVA

15 A
30 A

Power circuit
breaker
Siemens type

Adjust. Cross sect. of
current connected load
lead 3)

13.4 A 3VU1300-.MN00 1)
26.8 A 3VU1600-.MP00 2)

15 A
30 A

2.5 mm 2
6 mm 2

1)

Max. back-up fuse as per manufacturer: 80 A (gL) for supply voltages up to 500 V
Max. back-up fuse as per manufacturer: 200 A (gL) for supply voltages up to 500 V
3)
Lead cross section per EN60204 - installation type B1 - without taking correction factor into
account
2)

Fig. 3.7: Recommended fusing for the mains supply conductors

3.6. Mains supply earthing requirements
Earthed three-phase
mains

The TVD 1.3 can be connected to a grounded wye or delta system without
potential isolation.

Unearthed threephase mains

For ungrounded three-phase mains supplies (IT mains) there exists the
increased danger that overvoltages that are not permissible can occur
between the phases and the housing. The TVD 1.3 can be protected against
overvoltages
• if it is connected via an isolation transformer
(connect the neutral point of the transformer to the TVD with a PE rail) or
• if the machine is protected by overvoltage detector.
Connecting the TVD 1.3 via an isolation transformer offers the best protection
against overvoltage and the greatest possible operating safety.

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21

3. Electrical Connections

Overvoltages

• The periodic overvoltage on the TVD 1.3 between a phase (1U1, 1V1, 1W1,
2U1, 2V1, 2W1) and the housing may not exceed 1000 V (peak value).
• Non-periodic overvoltages, as per VDE 0160, between the phases and the
phases and the housing are permissible for the TVD 1.3 as depicted in the
diagram below.

UN+∆U
UN
3
2.6

∆U

2.4
2.3
2.2
∆U
2

2
1.8

UN

1.6

T

1.4
1.2
1.15
1.1
1
0.1

DGUespg

0.2

0.4 0.6

1 1.3

2

4

6 10
T (ms)

20

Fig. 3.8: Permissible non-periodic overvoltages as per VDE 0160

The TVD 1.3 can be connected to 3 x 480 V.
This means that the maximum permissible overvoltage equals:

480 V x √2 • 2.3 = 1560 V

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22

3. Electrical Connections

3.7. Commutation choke
In an effort to keep system perturbations as low as possible, the TVD should
always be operated with a commutation choke. See sections 3.3 and 3.4; for
power loss see dimension sheet in section 7.

3.8. DC bus circuit
Use the busbars contained in the connection accessories kit to connect the
drive modules to the TVD's DC bus circuit.
Use twisted single conductors for longer connections (maximum length equals
1 meter).

L1-DC bus reactor
For lead cross sections
see section 3.3
max. 1 m twisted

1L+ 1L-

max. 1 m
twisted

L-

L-

L-

10 mm2

L+

L+

L+

C1-DC bus
capacitor

Drive
module

TVD

Drive
module

Cross section depends on
the peak DC bus power
to be transmitted. At least
10 mm2 with the TVD 1.3-15
and 4 mm2 with the TVD 1.3-08
(max. 1 m twisted).
PDC in kW A in mm2
7,5
14
15

4
10
16

LL+
Drive
module

TVRZwkreis

Lead cross section per EN 60204 - installation type B1 - correcting factors not taken into account
Fig. 3.9:

Wiring the DC bus circuit

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23

3. Electrical Connections

3.9. DC bus smoothing choke
The TVD 1.3 must always be operated with a DC bus smoothing choke in the
" L+ line“.
Supply Module

DC bus smoothing choke

TVD 1.3-08-3
TVD 1.3-15-3

GLD 16 (or NAM 1.3-08)
GLD 17 (or NAM 1.3-15)

(See Section 3.3, for power loss see dimension sheet in section 7).

3.10. Additional DC bus capacitance
In plants where feed axes have to be accelerated and braked in rapid
succession, e.g., nipple machines, surface grinders, roll feeds, and so on, the
bleeder power and thus the power dissipation can be reduced by fitting
additional capacitors to the link circuit.
In a few applications, it is necessary to initiate a return of the drives with a
mains failure or an E-stop. The energy stored in the DC bus circuit can be used
for the return. The energy stored in the DC bus circuit can be increased by
additional capacitance.

Module

Maximum additional capacitance

TVD 1.3-08
TVD 1.3-15

Cmax = 70 mF
Cmax = 120 mF

3.11. Bridge circuit capacitance
In an effort to keep system perturbations as low as possible, the TVD must
always be operated with the NAM mains connection module or the bridge
capacitance CZ 1.2-01-7. See section 3.3. for details.

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24

3. Electrical Connections

3.12. Additional bleeder module TBM
The TVD 1.3 can be operated with an additional bleeder module of the TBM
1.2 type. The TVD and TBM combination gives the following power data:

Supply
module

Additional bleeder
module

(1)
PBD
kW

(2)
PBM
KW

(3)
Wmax
kWs

TVD 1.3-08
TVD 1.3-15

TBM 1.2-040-W1
TBM 1.2-040-W1

1.5
2.0

60
80

130
160

(1) PBD = Continuous bleeder power
(2) PBM = Peak bleeder power
(3) Wmax = Maximum regenerated energy

Caution !

In a worst case scenario, the sum of the peak regenerated power of
all simultaneously braking servo drives may not exceed the peak
bleeder power of the supply module. If such is not taken into
account during system design, then it is possible that the DC bus
voltage during an E-stop could climb to high to the point where the
drive equipment could be damaged.

TVD 1.3
LX7
EB

TBM 1.2

2
10 mm , twisted
max 1 m

L-

L+

L+

X 15

24 V 0 V
X3 7

EB

8

24 V 0 V
X 16

twisted

APTBM

min. 1 mm2
24 V - route leads and
EB leads separately

24 V-blower power
current consumption
140 mA

Fig. 3.10: Connecting the additional bleeder module TBM 1.2

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25

3. Electrical Connections

3.13. External bleeder resistor
Terminal block: X7/RB1/RB2
To reduce the amount of heat dissipated in the control cabinet, an external
bleeder resistor can be connected. This is installed outside the cabinet, e.g.,
on the rear panel of the cabinet. The bleeder resistor inside the TVD 1.3 is then
inoperative.
The voltage across the resistor can reach 450V DC.

Caution !
L1
L2
L3
DC bus
smoothing
reactor

Q1

L2

external
bleeder

L1

R1

X7
1U1

1V1

1W1

1L+

2L+

2U1

2V1

2W1

EPU+

RB1

RB2

EPU-

IB

EB
TVD/X7/3

Fig. 3.11: Terminal block X7 when operating the TVD 1.3 with an external bleeder

Resistors can be used as indicated in the specification below:
Supply module:

TVD 1.3-08

TVD 1.3-15

Resistance +/- 5%

R = 10 ohms

R = 5 ohms

Continuous power
(at 450C ambient
temperature)

P = 1 kW

P = 2 kW

Ppeak = 20 kW

Ppeak = 40 kW

Peak power
(for 1.5 s)
Maximum input
power
Protection category

• DOK-POWER*-TVD*1.3****-ANW1-EN-E1,44 • 02.97

Umax = 450V
Depends on installation site!

26

3. Electrical Connections

3.14. Supply to electronics and blower
Electronics

Supply voltage: 3 x AC 380...480V, 50...60 Hz
Connected load: 300 VA (for maximum utilization of supply to electronics)
The mains connections for the supply to power and electronics sections are
strapped when the unit is delivered. No additional mains connection is thus
required for the electronics section.
If a separate supply for the electronics is needed, e.g., to store the TVD's
diagnostic signals with mains disconnection, then the links between power
and electronics section can be removed. Short-circuit protection need only be
provided in the control cabinet for the connecting cable, e.g., miniature circutbreaker 3 VU 1300 -.MF00, 0,6 ... 1A, Siemens. Tap off electronics power
source between commutation chock and TVD.
L1
L2
L3
Q1

Commutation choke KD .. or
choke integrated in the NAM
DC bus
smoothing
reactor

F2
K2

L1

X7
1U1

1V1

1W1

1L+

2L+

2U1

2V1

2W1

EPU+

EPU-

RB1

RB2

IB

EB
TVD/X7/2

Fig. 3.12: Terminal block X7 for separate supplies to power and electronics sections

Blower

The TVD 1.3 needs no additional mains connection for the blower. If drive
modules are used that need a mains connection for cooling, this is done on the
drive module next to the TVD 1.3. The mains connector for the blower supply
must be ordered separately. The order number for the socket is 219 118.
supply
module

1)

2)

2)

1) Drive module without blower connection
TDM ...-...-300-W0
TDM ...-...-300-W1-000
TDA, DDS 2.1-W..
2) Drive module with blower connection
TDM ...-...-300-W1-115
TDM ...-...-300-W1-220
KDA, KDS, KDF, TFM

socket
part no. 219 118

Fig. 3.13: Blower connections of the drive module
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27

3. Electrical Connections

3.15. Electronics supply buffer capacitance
Terminal block: X7/EPU+/EPUConductor cross section: 1 mm 2
Additional electronic storage capacitance may be necessary if the drives have
to be stopped under position control in the event of a mains failure.
A mains failure is signalled by the UD output. Following this, the NC controller
must initiate controlled stopping of the drives within 10 ms, so that the drive
electronics remain operational. If the elapsed time before the drives feed back
power into the DC bus circuit exceeds 10 ms, then the user can boost the
supply to the electronics by means of additional capacitors.
An aluminium electrolytic capacitor is recommended due to the limited space.

Caution !

The voltage between EPU+ and EPU- can reach 450V DC. The
capacitor must therefore be rated for this voltage.
A maximum of 680 µF may be connected otherwise the TVD 1.3
could be damaged.

Back-up time

Storage capacitance
(for maximum utilitzation of supply
to electronics)

20 ms
50 ms
100 ms

150 µF
270 µF
680 µF

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28

3. Electrical Connections

3.16. Electronics supply and signal exchange
connections
Terminal connection X1 has two functions:
• voltage source to the drive electronics and
• signal exchange between supply and drive module(s)
The wire ribbon cable on the TVD 1.3 side has 16 pins. It is included in the
electrical connecting accessories of the drive module.

Conn. X1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

(2)

Conn. X1 (1)

bus connection
UD
BB
+15V
+15V
0VM
0VM
0VM
0VM
-15V
-15V
+24V
+24V
0VL
0VL
free

UD
BB
+15V
0VM
0VM
0VM
0VM
-15V
-15V
0VL
+24V

1
2
3
4
5
6
7
8
9
10
11
12

(1) Connector X1 for 12-pin units
(2) Connector X1 for 16-pin units

Bus16_12

Fig. 3.14: Transition from 16-pin bus connector to 12-pin bus connector

The wire ribbon connection is completed with a terminating plug for
verifying the wiring. Without it, the high voltage section cannot be powered
up. The TVD 1.3 can also be installed in the middle of the drive package.
In this case, it suffices if one end of the wire ribbon cable is terminated.
The terminating plug is part of the connecting accessories of the supply
module.

11 10

3 2

12-pin terminal conn.

3 2

16-pin terminal conn.

Endstecker

Fig. 3.15: End plug for terminating the bus connection

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29

3. Electrical Connections

3.17. Residual current operated devices
A current circuit breaker (fuse or power circuit breaker) should preferrably be
used to switch power off in the event of a short-circuit to the housing (ground).
If TT systems absolutely necessitate a residual current operated device
because of the size of the grounding resistance, then the following must be
taken into account.
In the case of switched-mode drive controllers, capacitive leakage currents
always flow to ground.
The degree of the leakage current depends on
• the number of drive controllers used,
• the length of the motor power cable and
• the grounding conditions on site.
The leakage current inevitably rises if steps are taken to improve the
electromagnetic compatibility of the machine (mains filter or shielded
conductors). Do not use residual current operated devices with leakage
currents of less than 0.3A!
False tripping can occur when switching inductances and
capacitances on (rf interference supression filters, transformers,
contactors and magnetic valves).

Commercial pulse-sensitive residual current operated devices (unit
designation _∩_∩_ ) do not guarantee that electronic equipment
with a three-phase bridge circuit (B6 circuit) is sufficiently protected.
The protection of the electrical equipment connected to such devices
together with equipment with B6 circuits can be impaired.

~

Warning!

Either residual current operated devices which switch off also with DCleakage current should be used, or an isolation transformer should be placed
in the mains supply line.
If isolation transformers are used, then the overcurrent protective devices
must be tuned to the impedance of the ground fault loop so that there is an
immediate tripping in the event of a fault. Connect the star point of the
secondary windings to the protective conductor of the machine.

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30

3. Electrical Connections

3.18. Control cabinet testing
No voltages other than those specified in the data sheet or in the
interface notes should be connected.
Caution

Prior to a high voltage test of the control cabinet, disconnect all
connections from the TVR.

3.19. Mounting the TVD 1.3 into the control cabinet
Installation
requirements

The power supply module and its associated drive modules are designed to
be installed in a control cabinet or a closed housing. They correspond to
protection classification IP 10, as per DIN 40 050.
The unit is protected from penetration of solid, foreign matter with a diameter
greater than 50 mm.
The unit is not protected against
• the admission of water or
• intentional access, for example, a touch of the hand. However, it does keep
flat surfaces away.

Arranging the drives

Arrange the drives so that the one requiring the greatest power and current is
as near as possible to the power supply.

Maximum number of
drives

With 12 pin bus connections there can be no more than a total of 16, viz., eight
to the left and eight to the right.
With 16 pin bus connections there can be no more than a total of 20, viz., ten
to the left and ten to the right.
The maximum load of the +24 V and ± 15 V may not be exceeded.
Power unit

Controllers with
high power

Controllers with
low power

Power connection

ATTENTION!
NEVER REMOVE OR INSTALL THIS
PLUGS WHILE VOLTAGE IS APPLIED.
BLACK CABLE ON THE BOTTOM!
Verbindung nie unter Spannung
lösen bzw. stecken.
Schwarze Leitung immer unten!

ATTENTION!
NEVER REMOVE OR INSTALL THIS
PLUGS WHILE VOLTAGE IS APPLIED.
BLACK CABLE ON THE BOTTOM!
Verbindung nie unter Spannung
lösen bzw. stecken.
Schwarze Leitung immer unten!

X5b
ATTENTION!
NEVER REMOVE OR INSTALL THIS
PLUGS WHILE VOLTAGE IS APPLIED.
BLACK CABLE ON THE BOTTOM!
Verbindung nie unter Spannung
lösen bzw. stecken.
Schwarze Leitung immer unten!

ATTENTION!
NEVER REMOVE OR INSTALL THIS
PLUGS WHILE VOLTAGE IS APPLIED.
BLACK CABLE ON THE BOTTOM!
Verbindung nie unter Spannung
lösen bzw. stecken.
Schwarze Leitung immer unten!

GATVR

Fig. 3.16: Preferred arrangement of the units inside the control cabinet
• DOK-POWER*-TVD*1.3****-ANW1-EN-E1,44 • 02.97

31

3. Electrical Connections

Spacing dimensions in
the control cabinet

110 ±0.5

TVR3
TVD1

TDA

155 ±0.5

TDM1
TDM2
DDS2

155 ±0.5

TDM1
TDM2
DDS2

110 ±0.5

TDM1
TDM2
DDS2

110 ±0.5

TVR3
TVD1

TDM1
TDM2
DDS2

TDA

TVR3
TVD1

TDM3
TDM4
DDS3

TDM1
TDM2
DDS2

TDM1
TDM2
DDS2

TVR3
TVD1

137 ±0.5

TDM3
TDM4
DDS3

TDA

92 ±0.5 74 ±0.5

TVR3
TVD1

110 ±0.5 110 ±0.5

TVR3
TVD1

TDA

110 ±0.5

110 ±0.5 92 ±0.5

TVD1
TVR3

200 ±0.5

TDM3
TDM4
DDS3

TDM3
TDM4
DDS3

155 ±0.5

NAM

TVD

TVR/T
eilung

Fig. 3.17: Spacing dimensions in the control cabinet

• DOK-POWER*-TVD*1.3****-ANW1-EN-E1,44 • 02.97

32

3. Electrical Connections

3.20. Heat loss inside the control cabinet
Basic losses in the TVD 1. 3 occur as a result of the generation of signal
voltages and high voltage power.

Basic losses
Power losses

Bleeder losses

Basic losses equal 75 W.
14 W per kW of DC bus continuous power in the TVD 1.3-08
17 W per kW of DC bus continuous power in the TVD 1.3-15
Bleeder losses are dependent upon the rotary drive energy, the potential
energy of imbalanced masses and the machine cycle in progress.

PRD =
PRD
tz
Wpotg
Wrotg

Wrotg + W potg
tz

= regenerated continous power or bleeder continuous power in kW
= cycle time in s
= sum of the potential energies in kWs
= sum of the rotary energies in kWs

Especially when running main drives (2AD; 1MB) check to make
sure that the continuous bleeder power and the maximum
regenerated energy do not exceed the values as listed in the data
sheets.

3.21. Safety clearance inside the control cabinet

300

The bleeder resistor in the TVD 1.3 is hot after power is shut down. Flammable
materials such as cables and cable channels must be kept at a distance of at
least 300 mm above and 40 mm to the side and to the front of the bleeder
resistor.

40

45

40

5

13

40

Bleeder resistor

TVR/Skizze3D

Fig. 3.18: Safety clearances inside the control cabinet
• DOK-POWER*-TVD*1.3****-ANW1-EN-E1,44 • 02.97

33

3. Electrical Connections

3.22. Front view of the TVD 1.3

Bridge capacitor
connection

P N

PE-conductors
central ground
for each drive
controller

Terminal block for
mains and DC bus
reactor
connections

X7

Diagnostics Display

X7
L-

DC bus for
the power
supply of the
drives

L+

Connection
of bus cable
of signal voltage
supply and drive
monitoring

X9
TM

POWER SUPPLY

X1

Typ:
Serien-Nr.:

RESET

S2

RESET key

X2

X3

X5

Plug-in terminals for:
• control inputs
• status messages
• 24V, ± 15V outputs

X4

FATVD12Ver

Fig. 3.19: Front view of supply module TVD 1.3

• DOK-POWER*-TVD*1.3****-ANW1-EN-E1,44 • 02.97

34

4. TVD 1.3 Interconnections

4.

TVD 1.3 Interconnections

The interconnections for mains and the DC bus of the TVD recommended by
INDRAMAT illustrate the operating principles of the unit. This section outlines
several interconnect configurations. Just which configuration is selected
depends on the functions and the sequence of actions required for the entire
machine and is the responsibility of the machine builder.

4.1. Optional Control Possibilities

braking the
drives with faulty
drive electronics

controlled braking
with an E-stop or a
power failure

with DC bus
dynamic braking
without DC bus
dynamic braking
by the electronics
of the drive
by the NC control
unit

Fig. 4.1: Optional control possibilities

Stopping the drives with
faulty drive electronics
with or without DC
dynamic braking

The DC bus is short-circuited for braking the drives to a standstill as an
additional safety precaution if there is ever a fault in the drive electronics.

With DC bus dynamic braking, synchronous motors are always braked to a
standstill regardless of whether the drive electronics are functional or not.
Without DC bus dynamic braking, synchronous motors can not be braked with
faulty drive electronics.
Asynchronous motors cannot be braked if the DC bus is short-circuited!

Braking with an E-stop
or mains failure at
maximum torque by the
drive electronics or in a
position loop by the
NC control unit

Drives are generally brought to a standstill by the drive control with an E-stop
or mains failure.
In the event of an E-stop or if the drive-internal monitors are tripped, then drive
control switches to zero command value and there is a regulated braking of the
drives at maximum torque.
In some cases (e.g., electronically coupled tooth gear machines), it may be
necessary for the CNC to bring the drives to a standstill in an E-stop situation
or a mains failure.
There is then a regulated braking of the drives by the NC control unit with an
E-stop or if the drive-internal monitors are tripped.

• DOK-POWER*-TVD*1.3****-ANW1-EN-E1,44 • 02.97

35

4. TVD 1.3 Interconnections

4.2. TVD interconnect with DC bus dynamic braking
With this variant, a high level of safety with a low level of expenditure is
achieved. The monitoring devices built into the drive system are used most
effectively, in this case:

Application

• if the TVD 1.3 is supplying feed drives only
• and if asynchronous spindle drives and synchronous feed drives are
operated from the same TVD.

Features

The NCB link on the TVD (X3/1 - X3/2) must not be jumpered.
It is posible to brake synchronous motors (permanently excited) with the DC
bus dynamic brakes whether the drive electronics are operational or not. DC
bus dynamic braking occurs only if there is a fault in the drive. Therefore, if
the E-stop button is pressed, asynchronous drives are also braked.
If there is an E-stop or one of the monitor circuits of the TVD is tripped, for
example, by a power failure, then the drives are braked at maximum torque
under drive electronic regulation.
Source of danger:

Warning!

The DC bus dynamic brake protects machines in the event of drive
failure. It alone does not function to protect personnel. In the event of
faults in the drive and the supply module, uncontrolled drive
movements are still possible even if the DC bus dynamic brake (X2/
2 = 0) is activated.
Possible cauess:

Injury to personnel is possible depending upon the type of machine.
How to avoid:

Additional monitoring and safety devices can be installed on the
machine side.

Mode of operation

When the E-stop button is pressed, the main contactor in the TVD 1.3 drops
out immediately. The drive enable signal of the drives is dropped by means of
an auxiliary contact of the main contactor. This leads to a drive-internal
switching of the velocity command to zero in all drives in the drive packet. All
drives are braked under control.
A drive fault signal to the supply module (Bb1 contact), a fault signal from the
NC (servo fault), or an overtravelling of the limit switch cause the main
contactor to be switched off and the DC bus dynamic brake to be applied.

DC bus
short-circuit
t3

OFF
ON

t1

t1

t1

K1
(X5/3-4)
DC bus
voltage
t2

UD contact

t2

Drive enable signal
from control unit
t1 ≥ 200 ms; t2 = 1.25 ... 1,4 s; t3 ≥ 40 ms

SVTVDmZW

Fig. 4.2: Path of the signal when powering up the TVD
• DOK-POWER*-TVD*1.3****-ANW1-EN-E1,44 • 02.97

36

4. TVD 1.3 Interconnections

Functionalities: • with DC bus dynamic braking
• regulated braking by drive electronics with an E-stop
L1
L2
L3
bridged at
delivery

Q10

2U1 2V1 2W1

Q1

1U1 1V1 1W1

ϑ

X2/1

X3/1
NCB open

X4/1
X3/2

Bb1
X4/2
S2
ZKS

K1

Netzschütz
Haltebremse
Achsendlage
Verriegelung Schutztüre

CNC
X2/2
1

X9/L+

X2/3

S1

power supply
drive module

OFF
S4

X9/L-

X2/4
DC bus
dynamic
braking

X2/5
ON

S5

K1

converter
release

X2/6
&

On delay 1.4 s

ready

1

3

2

4

+24V
+/- 10%

X5/1

RF
K4
X5/3
K1

1)

K1

TVD

TVD

X5/2

X5/4
X4/3
UD

Y1
X4/4

U

Y2
U

Bb
RF

RF
U

RF
drive
module

K4
1)

TVD

Bb1 = supply module ready (drive system)
Bb = drive module ready
CNC = lag error message from the control unit
(use only contact that does not open
when E-stop switch opens)
K1 = mains contactor in supply module
K4 =holding brake control 1)
Q1 = power supply fuse
Q10 = main switch
RF = drive enable signal of the control unit
S1 = E-stop
S2 = axis end stop
S4 = power off
S5 = power on
Y1 = holding brake for feed axis with electrical release;
note the release delay! Speed command value
100 ms after RF on
Y2 = safety door locks

0V
1) Only with holding brakes for feed drives that are not controlled by the drive module.
SS1TVR

Fig. 4.3: Controlling the TVD 1.3 with DC bus dynamic brake

• DOK-POWER*-TVD*1.3****-ANW1-EN-E1,44 • 02.97

37

4. TVD 1.3 Interconnections

4.3. TVD interconnect with E-stop relay with DC bus
dynamic braking
Excellent safety at low cost is achieved with this variant. The monitoring
devices built into the drive system are used most effectively.

Application

• in larger plants where monitoring or numerous E-stop switches are required,
• if the TVD is supplying feed drives only and
• if synchronous and inductance drives are operted from the same TVD.

Features

The NCB link on the TVD (X3/1 - X3/2) may not be jumpered.
DC bus dynamic braking always brakes synchronous motors to a controlled
standstill regardless of whether the drive electronics are still functioning or not.
DC bus is short-circuited only if there is a fault in the drives. If the E-stop relay
is switched off, then inductance main drives can be braked as well.
If there is an E-stop or one of the monitor circuits of the TVD is tripped, for
example, with a power failure, the drives are braked at maximum torque under
drive regulation.
Source of danger:

Warning!

The DC bus dynamic brake protects machines in the event of drive
failure. It alone does not function to protect personnel. In the event of
faults in the drive and the supply module, uncontrolled drive
movements are still possible even if the DC bus dynamic brake (X2/
2 = 0) is activated.
Possible cauess:

Injury to personnel is possible depending upon the type of machine.
How to avoid:

Additional monitoring and safety devices can be installed on the
machine side.

Mode of operation

When the E-stop button is pressed, the main contactor in the TVD drops out
immediately. The enable signal of the drives is dropped by means of an
auxiliary contact of the main contactor. This leads to a drive-internal switching
of the velocity command to zero in all drives in the drive packet. All drives are
braked under control.
A drive fault signal to the TVD 1.3 (Bb1 contact), a fault signal from the NC
(servo fault), or an overtravel signal from the overtravel limit switch cause the
main contactor to be switched off and the DC bus dynamic brake to be applied.
DC bus
dyn. brake
t1

OFF

t3

K1
(X5/3-4)
DC bus
voltage
UD contact
t2

Drive enable from
control unit

t2

t1 ≥ 200 ms; t2 = 1.25 ... 1.4 s; t3 ≥ 40 ms

SVTVDmNA

Fig. 4.4: Signal path when powering up a TVD

• DOK-POWER*-TVD*1.3****-ANW1-EN-E1,44 • 02.97

38

4. TVD 1.3 Interconnections

Functionalities: • immediate shutdown with E-stop relay
• with DC bus dynamic brake
• controlled braking by drive electronics in E-stop
L1
L2
L3
bridged at
delivery

Q10

Q1

2U1 2V1 2W1

1U1 1V1 1W1

ϑ

X2/1

X3/1
NCB open

X4/1
X3/2

Bb1
ZKS

X4/2
S2
K1
CNC
X2/2
1

X9/L+

X2/3
A10
OFF

X9/L-

X2/4
DC bus
dynamic
brake

X2/5
K1

converter
release

X2/6
&

+24V
+/- 10%

1

TVD

ON delay 1.4 s

ready

3

2

A10 = E-stop relay
Bb1 = supply module ready
(drive system)
Bb = drive module ready
CNC = lag error message from control unit
(use a contact that does not open when
the E-stop switch opens)
K1 = mains contactor in supply module
K4 = holding brake control 1)
Q1 = power supply fuse
Q10 = main switch
RF = drive enable signal fo the control unit
S1 = E-stop
S2 = axis end stop
Netzschütz
S4 = Power off
Haltebremse
S5 = Power on
S11 = safety door monitoring
S12 = safety door monitoring
Y1 = holding brake with electrical release for feed drives;
note release delay! after nach RF on

control voltage

RF
X5/3
K1

K4

TVD

1)

S11

K1

S4

X5/4
X4/3

S1

UD

Y1

X4/4

S5

S12
safety doors
closed

U
Bb

RF RF
U

RF
drive
module
A10

K4
1)

E-stop relay

0V
1) Only with holding brakes of feed
drives that are not controlled by the
drive module.

Example:
Depending on the safety requirements at the
machine, additional monitoring devices and
locks may be necessary!

SS2TVR

Fig. 4.5: TVD 1.3 interconnect with DC bus dynamic braking

• DOK-POWER*-TVD*1.3****-ANW1-EN-E1,44 • 02.97

39

4. TVD 1.3 Interconnections

4.4. TVD interconnect without DC bus dynamic braking
Application

If the uncontrolled coasting of the drives cannot damage the plant.
Typical applications
• if the TVD supplies inductance drives only and
• if the end-stops of the feed axes are sufficiently damped.

Features

The NCB link on the TVD (X3/1 - X3/2) may not be jumpered.
The DC bus voltage is not short-circuited. In the case of inductance drives,
the DC bus dynamic brake has no additional braking effect when there is a fault
in the drive electronics. If the DC bus is short-circuited, inductance drives can
no longer be braked under drive control.
With an E-stop or if one of the monitoring circuits of the TVD is tripped, e.g., as
a result of a power failure, then the drives are braked at maximum torque under
drive regulation.

Mode of operation

When the E-stop key is pressed, the main contactor in the TVD drops out
immediately. The drive enable signal of the drives is dropped by means of an
auxiliary contact of the main contactor. This leads to a drive-internal switching
of the velocity command to zero in all drives in th drive packet. All drives are
braked under control.

Source of danger:

Coasting of the drives with faulty drive electronics.
Caution !

Possible consequences:

Machine damage.
How to avoid:

• End stops of feed axes must be sufficiently damped.
• Use motors with mechanical brakes.

t3

OFF
ON

t1

t1

K1
(X5/3-4)
DC bus
voltage
t2

UD contact

t2

Drive enable signal
from control unit
t1 ≥ 200 ms; t2 = 1.25 ... 1.4 s; t3 ≥ 40 ms

SVTVDoZW

Fig.4.6: Signal path when powering up the TVD

• DOK-POWER*-TVD*1.3****-ANW1-EN-E1,44 • 02.97

40

4. TVD 1.3 Interconnections

Functionalities: • without DC bus dynamic brake
• controlled braking by the drive electronics in E-stop
L1
L2
L3
bridged at
delivery

Q10

2U1 2V1 2W1

Q1

1U1 1V1 1W1

ϑ

X2/1

X3/1
NCB open
X3/2
X4/1
Bb1
X4/2

K1

for diagnostics

X2/2
1

X9/L+

X2/3

S1

power supply
of drive module

OFF
S4

X9/L-

X2/4
DC bus
dynamic
brake

X2/5
ON

S5

K1

converter
release

X2/6
&

On delay 1.4 s

ready

1

+24V +/- 10%

2

3

4
X5/1

RF
K4
X5/3

1)

K1

TVD

TVD

X5/2

K1
X5/4
X4/3
UD

Y2

Y1
X4/4

U

U

Bb
RF
K4

TVD

RF
drive
U module

RF

Bb1 = supply module ready (drive system)
Bb = drive module ready
K1 = mains contactor in supply module
K4 =holding brake control 1)
Q1 = power supply fuse
Q10 = main switch
RF = drive enable signal of the control unit
S1 = E-stop
S4 = power off
S5 = power on
Y1 = holding brake for feed axis with electrical release;
note the release delay! Speed command value
100 ms after RF on
Y2 = safety door locks

1)
0V
SSTVR/3

1) Only with holding brakes for feed drives that are not controlled by the drive module.

Fig. 4.7: TVD interconnect without DC bus dynamic braking
• DOK-POWER*-TVD*1.3****-ANW1-EN-E1,44 • 02.97

41

4. TVD 1.3 Interconnections

4.5. TVD interconnect for a position-controlled braking
of the drives
Application

Drives which are coupled electronically as if by gearboxes under the control
of an NC cannot normally accept an angular positioning error in the event of
a power failure.

Features

The NCB link on the TVD (X3/1 - X3/2) must be jumpered. The mains
contactor may not switch the drive enable signal off.
The DC bus voltage is not short-circuited so that energy is available for a
position-controlled stopping of the drives.
During E-stop or if one of the monitor circuits of the TVD, e.g., during a power
failure, is tripped, then the drives will be brought to a standstill under positioncontrol through the NC.
The energy stored in or regenerated to the DC bus circuit must be greater than
the energy required to excite the inductance machines or for return movements.

Mode of operation

When the E-stop chain opens, the main contactor in the TVD drops out
immediately. The NC must bring the drives to a stop under position control.

Source of danger:

A faulty power supply is not signalled to the drives when the NCB link
is installed.
Caution !

Possible consequences:

There is an uncontrolled braking of the drives with a power failure.
The degree of damage depends upon the type of machine.
How to avoid:

If the UD contact opens, then the NC must bring the drives to a
position-controlled standstill.

t3

OFF
ON

t1

t1

K1
(X5/3-4)
DC bus
voltage
t2

UD contact
Drive enable from
the control unit

t2
1)

1) Do not switch drive enable signal off until the drives are standing stil.
t1 ≥ 200 ms; t2 = 1.25 ... 1.4 s; t3 ≥ 40 ms

SVTVDzLBA

Fig. 4.8: Signal path when switching on a TVD

• DOK-POWER*-TVD*1.3****-ANW1-EN-E1,44 • 02.97

42

4. TVD 1.3 Interconnections

Functionalities: • without DC bus dynamic brake
• controlled braking by the NC control unit in E-stop
L1
L2
L3
Q1

bridged at
delivery

Q10

2U1 2V1 2W1

1U1 1V1 1W1

ϑ

X2/1

X3/1
NCB
X3/2
X4/1
Bb1
X4/2

K1

for diagnostics

X2/2
1

X9/L+

X2/3

S1
OFF

power supply
drive module
S4

X9/L-

X2/4
DC bus
dynamic
brake

X2/5
S5

ON

X2/6

K1

converter
release

Netzschütz
Haltebremse

&

On delay 1.4 s

TVD

ready
1
+24V
+/- 10%

2

3

4

5
X4/3

X5/1
K4

1)

K1

UD

TVD
X4/4

X5/2
RF
Y2

Y1

Bb

K4

RF RF RF
drive
module

U

U

control
unit

U

Bb1 = supply module ready (drive system)
Bb = drive module ready
K1 = mains contactor in supply module
K4 =holding brake control 1)
Q1 = power supply fuse
Q10 = main switch
RF = drive enable signal of the control unit
S1 = E-stop
S2 = axis end stop
S4 = power off
S5 = power on
UD = signal from KVR; power feed working
Y1 = holding brake for feed axis with electrical release;
note the release delay! Speed command value
100 ms after RF on
Y2 = safety door locks

1)
0V
1) Only with holding brakes for feed drives that are not controlled by the drive module.

SS4TVR

Fig. 4.9: Control of theTVD for a position-controlled braking of the drives
• DOK-POWER*-TVD*1.3****-ANW1-EN-E1,44 • 02.97

43

5. Terminal Descriptions

5.

Terminal Descriptions

5.1. DC bus short-circuiting
Terminal X2/1 - X2/2

Input ZKS

Voltage: 24 V DC

Current consumption: 270 mA

Input

open

closed

Operating status

Power off,
DC bus
short-circuit
closed

Power on,
DC bus
short-circuit
open

The TVD main power contactor can be pulled in only if the ZKS input is closed.
The DC bus is short-circuited if the ZKS input is open. This is an additional
safety feature for the machine for braking drives to a standstill with a fault in
drive electronics.

Switching rate

Maximum of 25 operating cycles per minute (w/o additional capacitance with
drive standing)

Z=
CZU
Jg
PZK

ω
Z

2 • P ZK
Czu • 425 2 + Jg • ω 2

• 60

= DC bus capacitance in F
= Total moment of inertia of mass in kgm2
= Power of the ZK resistor in W
220W with TVD 1.3-08
440W with TVD 1.3-15
= Angular speed in rad / s
= Switching rate per minute but max. 25 / min.

Fig. 5.1:Switching rate with additional capacitance and rotating motor

5.2. Power off
Terminal X2/3 - X2/4

Input OFF

Voltage: 24 V DC

Current consumption: 270 mA

Input

open

closed

Operating status

Power off

Power on

The main power contactor in the TVD can be pulled in only if the OFF input is
closed. If the OFF input is open, for example during an E-stop, then the main
power contactor in the TVD opens immediately.

5.3. Power on
Terminal X2/5 - X2/6

Input ON

Voltage: 24 V DC

Current consumption: 270 mA

Input

open

closed or open and
closed when latched

Operating status

Power off

Power on

If ZKS and OFF inputs are closed and the internal drive-ready signal is
present, closing the ON input will cause the TVD main contactor to pull in.
Next, the main contactor is latched on. The ON signal is a pulse and must hold
high for at least 200 ms.
Switching rate:
Service life:

max. 25 operating cycles per minute
2.5 million operating cycles

• DOK-POWER*-TVD*1.3****-ANW1-EN-E1,44 • 02.97

44

5. Terminal Descriptions

5.4. Stopping the drives in an E-stop or a power failure
NCB Link

Input – Terminal X3/1 - X3/2
jumper

open

closed

controlled braking
with an E-stop or a
power failure

by the drive
electronics

by the
NC control

If the NCB link is open or not jumpered, a power failure or a drive fault in the
drive ystem is signalled to all the drives. The drives are braked at maximum
torque. In addition, if there is a drive fault, the internal ready signal of the TVD
is dropped which leads to shutdown of the power supply.
In some applications, for example, electronically coupled gear cutting machines,
the drives have to be braked postion-controlled through the CNC if there is an
E-stop or a power failure.
Do not use the NCB link for digital drives with SERCOS interface.
Position-controlled braking is done without the NCB link by
programming the fault reaction directly into the drive. The NCB link
prevents the signalling of a faulty power supply to the drive.
With the NCB jumpered, the following faults are not signalled to the drives:
• Faulty power supply
– mains power failure / missing phase
– DC bus voltage less than 270 V
• Drive faults
– open wire-ribbon connection or missing terminating connector
– low-voltage faults +24 VL/±15 VM
– overcurrent in the TVD high-voltage section
– bleeder overload
– overtemperature in the TVD heatsink
Because these monitor circuits are not tripped, the drives can be braked to a
standstill under position control if there is a power failure. The power regenerated
during braking must be greater than the power consumption of the TVD.
The power supply of the TVD is always switched off by the internal " ready "
signal in the presence of a drive fault.

Source of danger:

With the NCB link closed or jumpered, the command to zero of the
drives is suppressed.
Caution !

Possible consequences:

The drives can coast uncontrolled. Damage to the machine depends
upon the type of machine.
How to avoid:

The CNC control must evaluate the UD contact and bring the drives
to a standstill when this contact is open.

• DOK-POWER*-TVD*1.3****-ANW1-EN-E1,44 • 02.97

45

5. Terminal Descriptions

5.5. Signal Voltages
Signal voltages can be accessed on terminal strip X3. These terminals are
designed for test and measurement purposes. If these voltages are used
exterior to the TVD, ensure that no noise or interference is coupled in (shortconnections, shielded leads, etc.).
The signal voltage outputs are short-circuit protected. To prevent damage to
the drives, the maximum permissible loading must not be exceeded.
X3/3

measuring voltage max.100 mA

X3/4

0VM

reference potential of measuring voltage

X3/5

-15VM

measuring voltge max.100 mA

X3/6

ground

shielding

X3/7

+24VL

load voltage max. 2 A

X3/8

Output Bb1

+15VM

0VL

reference potential load voltage

5.6. " Ready " status
Potential free contact – terminal X4/1 - X4/2
Maximum load: DC 24 V/1 A; AC 250 V/1A
Operating status

Relay
de-energized

Fault

ready

Output

open

open

closed

The Bb1 contact of the TVD is very important and has special significance. The
Bb1 contact signals whether the drive packet is ready for swtich on power. The
TVD's internal interlocks will not permit the main contactor to pull in until Bb1
is closed.
If there is a fault, the main contactor drops out and the Bb1 contact opens. If
Bb1 opens, controlled braking of the drives is no longer assured. Therefore it
is used to trigger DC bus short-circuit.
Bb1 closes when power for electronics is applied to terminal block X7/2U1/
2V1/2W1 and there is no fault.
Bb1 opens for the following faults:
• tachometer fault
• overtemperature in the drive
• overcurrent in the drive module
• signal voltage fault ±15 VM / +24 VL
• an open in the wire-ribbon connection or missing wire-ribbon termination
• TVD heatsink tempreature too high
• overcurrent in the TVD high-voltage section
• overvoltage
• bleeder overload

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46

5. Terminal Descriptions

NCB bridge

DC bus
voltage & lt; 50V

Command value to
zero
of the drives with
a power failure

R Q
mains voltage OK
S Q

Mains monitoring
≥1

&
DC bus
voltage ≥ 270V

UD
open with
fault

power OK

X1.1

&

BVW
open with
fault

regenerated P & gt; 80%
power
too high
P & gt; 100%

BLEEDER
overload
S Q
R Q

TVW
open with
fault

T
emperature
monitoring TVD 1.3

Release of
mains
contactor
in TVD

KK overtemperature
S Q
30 sec.

R Q

&
+24VL, ±15VM

+24V ±15V

&

X1.2
drive ready
for power

Bb1
open with
fault
Bb1 closed

DC bus cannot
be loaded
overcurrent
S Q

Overcurrent in TVD 1.3

R Q

overvoltage fuse
(RESET not possible)

overvoltage
suppressor

1
DC bus
voltage ≤ 440V

X1.15
release spindle
drive
TVD/Übwach

Fig. 5.2:

Monitoring and diagnostics systems of the TVD 1.3

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5. Terminal Descriptions

5.7. Power OK
Output UD

Potential free contact – terminal X4/3 – X4/4
Maximum load: DC 24 V/1 A; AC 250 V/1A
Operating status

Relay
de-energized

Fault

Power
OK

Output

open

open

closed

The UD contact acknowledges proper operation of the power system.
UD opens for the following faults:
• mains power failure / missing phase
• DC bus voltage lower than 270 V
The reaction of the drive sytem to these faults depends on the NCB link. See
section 5.4 for details.
If CNC-controlled braking is required, the drives must be stopped by the
master controller when the UD contact opens.

5.8. Regenerated power too high
Output BVW

Potential free contact – terminal X4/5 – X4/6
Maximum load: DC 24 V/1 A; AC 250 V/1A

Operating status

Relay
de-energized

Regenerated
power
too high

Regenerated power
within
permissible limits

Output

open

open

closed

The bleeder prewarning contact opens if the regenerated continuous power
is greater than the continuous bleeder power. If the bleeder load continues to
climb and reach thermal overload, then the main contactor in the TVD
interrupts the power supply and Bb1 opens.
The reaction of the drive system to this fault depneds on the NCB link. See
section 5.4 for details.

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48

5. Terminal Descriptions

5.9. Temperature Pre-Warning
Output TVW

Potential free contact – terminal X4/7 – X4/8
Maximum load: DC 24 V/1 A; AC 250 V/1A
Operating status

Relay
de-energized

Temperature
too high

Output

open

open

Temperature
within
permissible limits
closed

The temperature prewarn contact opens if the heatsink temperature is too
hich. After 30 seconds, the mains contactor in the TVD interrupts the power
supply and the Bb1 contact opens.
The reaction of the drive system to this fault depends on the NCB link. See
section 5.4 for details.
If CNC-controlled braking is required, the drives must be stopped within 30
seconds if a temperature pre-warning contact in the TVD or one of the drive
modules opens.

5.10. Mains contactor de-energized
Output K1NC

Potential free contact – terminal X5/1 – X5/2
Maximum load: DC 24 V/1 A / AC 250 V/1 A

Operating status

contactor de-energized

contactor energized

Output

closed

open

The K1NC output can be interrogated to see if the mains contactor is deenergized. This status can be used as a condition for enabling door interlocks,
for example.
There is positively-driven operations between the K1NC and the main poles
in the TVD 1.3.

5.11. Mains contactor energized
Output K1NO

Potential free contact – Terminal X5/3 – X5/4
Maximum load: DC 24 V/1 A / AC 250 V/1 A
Operating status

contactor de-energized

contactor energized

Output

open

closed

The K1NO output can be interrogated to see if the mains contactor is
energized. The closed status of K1NO can be used as a condition for the
application of the enable signal to the drives. (Exception: see section 4.5.)

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49

6. Troubleshooting

6.

Troubleshooting

Long hours spent troubleshooting and repairing drive components on the
machine are unacceptable because of production downtime.
INDRAMAT AC drive components can easily be replaced as entire units with
no adjustment required because of their construction. This means that
whenever there is a fault, servicing is reduced to localizing the problem to the
motor, the power supply, or the drive module and then simply replacing the
faulty component.

6.1. Localizing the fault
Faulty drive motions can be caused by interactions of various components,
namely, the CNC, power supply to drive modules, mechanics, position
measurement devices and so on. A fault in one of the above or their improper
combination or tuning may be the source of the fault. The TVD 1.3 provides
extensive diagnostics for rapid localization of faults.
There is an increased chance of an accident when a fault occurs. Personnel,
machines and equipment are at risk.

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50

6. Troubleshooting

Danger from voltage
carrying parts

Dangerous voltage can occur at the following connections:
- At all connections to the power supply and its associated chokes and
capacitors, and especially at connections to mains 1U1, 1V1, 1W1 and 2U1,
2V1, 2W1, as well as X13 und X14 of the blower.
- At the drive modules, motor and connections to the motor.
Source of danger:

Electrical voltages of up to 700 V!
Danger !

Possible consequences:

Danger to life and limb and property damage! Working on the range
of energized components can lead to fatal injuries. This particularly
applies to the supply modules and its related chokes, capacitors and
fuses as well as drive modules, motor and motor connections.
How to avoid:

Only trained and qualified electrical personnel may be permitted to
work on the machine.
Turn off all power to the installation for all work in the hazardous area.
Lockout the installation so that power cannot be turned on.
Prior to starting work, use measuring devices to check whether the
components of the machine are still energized (e.g., capacitors and
so on). Wait the discharge time of the DC bus which is approximately
five minutes!
Use only that measuring and testing equipment that is suitable and
appropriate to the application.
Do not run motors. Voltage is present at the motor connections if the
motor is in motion. Vertical axes must be secured against movement
if the machine is switched off.
Insert protective caps into cables or open cable ends of power plugin connectors when replacing drive components.

Do not power up until the all safety shrouds and devices for supply and drive
modules are mounted back into place.

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51

6. Troubleshooting

Danger from moving
parts

Source of danger:

Unexpected and unintentional axis movements!
Possible consequences:

Danger !

Danger to life and limb and property damage! Problems with the
machine and when locating the problem represent, in particular,
situations with an increased risk.
How to avoid:

Personnel must not remain in the hazardous area of the installation.
Protective devices such as safety screens, covers and light barriers
must not be disabled. There must be free, ready and easy acess to
the E-stop button.

Replacing units

Required for replacement are:
• a lifting device (dependent upon the weight of the device to be replaced)
• and a replacement unit of the same type.
Please comply with the procedures below:
1. Shut the power to the machine off and secure the device against being
unintentionally or accidentally switched back on.
2. Using suitable equipment, check whether the machine is not conducting
electricity. Wait the discharge time. Motors must be standing still. Vertical
axes must be secured agianst movement.
3. Using the rating plate, make sure that both units are the same. The
replacement unit must be of the same type as the unit being replaced.
4. Release all connections of the defective unit.
5. Release the fixing screws and remove the unit from the control cabinet. Use
the lifting device, e.g., a crane, if necessary.
Source of danger:

Electrostatic discharges are possible!
Possible consequences:

Caution !

The discharge could damage electronic components and equipment.
How to avoid:

Before replacing plug-in modules, touch a grounded object such as
the control cabinet door. This discharges the human body.

6. Hang the replacement unit onto the fixing screws by using the lifting device.
Tighten the screws.
7. Reconnect the unit as per the interconnection diagrams of the machine
manufacturer.
8. If vertical axes have been secured prior to the replacement procedure, then
remove the device with which these were secured.
The replacement is completed. The machine can be restarted.

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52

6. Troubleshooting

6.2. Diagnostic display
Note that the signals are only valid if the " +24V,+/-15V " -message is displaying
a stead green light!

OFF

LEDs

Flashing

Signal voltages

Signal voltages
faulty

H1B
green

+24V / ±15V

H2B
green

Bb1

Fault in supply
module or in drive
(1)

MAINS

Connected load
faulty,
phase missing or
mains voltage
too low

H3B
green

" Steady " light

in order

Supply module
and drives
are fault-free
connected
load

in order

POWER

mains contactor not
on or faulty,
power rectifier
faulty

I-FAULT

current in power
section
within permissible
limits

power on with short
circuit in TVD, in the
drive, in the cable or
motor

P-FAULT

braking power of
drive within permissible
range

braking output of
drive may not be
permitted to rise
further

shutdown due to
excessive braking
power
(1)

H3A
red

T-FAULT

unit temperature
within
permissible range

unit temperature too high,
power shutdown in
30 seconds

power shutdown
due to excessively
high
unit temperature (1)

H4A
rot

U-FAULT

voltage in power section
has not exceeded its
maximum value

H4B
green

H1A
red

H2A
red

DC bus voltage

in order
shutdown due to
overcurrent, short-circuit
in TVD, in drive, in cable
or in motor (1)

overvoltage
fuse has been
tripped
TVD/Diagnoseanz

(1) Signal and unit locking is stored.
This can be cleared by pressing the reset key or by switching the
electronics power source back on.

Fig. 6.1:

Diagnostics displays of the TVD 1.3

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6. Troubleshooting

6.3. Definition of the displays

B

A

+24V / ±15V

H1

I-FAULT

Bb1

H2

P-FAULT

LED green

MAINS

H3

T-FAULT

LED red

POWER

H4

U-FAULT
DATVD1.3

Fig. 6.2: Diagnostics displays on the TVD 1.3
B
+24V / ±15V

A
H1
H2

Bb1

B

A

+24 V / ±15 V

H1

Bb1

H2

+24 V/±15 V
Display green:
Signal voltages are OK.

+24 V / ±15 V / +5 V
Display dark:
Signal voltage faulty.

(Operating status)

(Fault - not stored)

Cause 1: Missing or faulty mains input voltage for electronic supply.

Remedy

Check mains fuse in the control panel.
Cause 2: Maximum load of the signal voltages exceeded.

Remedy

1. Disconnect wire-ribbon connection (X1) to the drive modules
and check voltages at X3.
2. Disconnect signal voltages and check for short-circuits
(+ 24 V: max. 2 A; ± 15 V: respect. max. 100 mA).

B

A

+24 V / ±15 V

H1

Bb1

H2

B

A

+24 V / ±15 V

H1

Bb1

H2

Bb1
Display green:
No faults in supply modules or drives.

Bb1
Display dark:
Fault in supply module or drive.

(Operating status)

(Fault - stored)

Cause 1: Fault in supply module

Remedy

Check the remaining diagnostics displays of the supply module.
Cause 2: Drive module fault

Remedy

Check diagnostics display of the drive module.
Cause 3: Fault in the signal voltage bus connection

Remedy

Check bus cable at X1 and end connector of the bus connection
should be checked whether properly in place.

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6. Troubleshooting

B

A

MAINS

H3

POWER

H4

B

A

MAINS

H3

POWER

H4

MAINS
Display green:
Power supply OK.

MAINS
Display dark:
Power supply faulty.

(Operating status)

(Fault - not stored)

Cause :
Main fuse acutated, mains phase at X7 missing or mains
voltage too low.

Remedy

B

A

MAINS

H3

POWER

H4

B

A

MAINS

H3

POWER

H4

Check main connection (rated value: 3 x 380...480 VAC ± 10 %)
POWER
Display green:
Internal mains contctor ON; DC bus voltage OK.

POWER
Display dark:
Mains contactor not on; fault in DC bus.

(Operating status)

(Fault - not stored)

Cause 1: Mains contactor not on

Remedy

Check circuit at X2/6 (+ 24 VL against 0 VL).
Cause 2: DC bus smoothing choke missing or improperly connected

Remedy

Check connection of smoothing bus choke (between X7/1L+ and X7/
2L+).
Cause 3: Faulty rectifier

Remedy

Replace unit.

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55

6. Troubleshooting

B

A
H1

I- FAULT

H2

P- FAULT

B

A
H1

I- FAULT

H2

P- FAULT

B

A
H1

I- FAULT

H2

P- FAULT

I-FAULT
Display dark:
Current in power section within permissible range.

(Operating status)

I-FAULT
Display flashing:
(Fault - not stored)
Power up OK even though there is a short circuit in the unit, drive module, cable
or motor.
I-FAULT
Display red:
(Fault - stored)
Shutdown was triggered due to overcurrent in power section.
Cause 1: Defective drive module or damaged motor power cable.Short circuit
in the motor. DC bus smoothing choke is disconnected.

Remedy

Remedy

B

A
H1

I- FAULT

H2

P- FAULT

B

A
H1

I- FAULT

H2

P- FAULT

B

A
H1

I- FAULT

H2

P- FAULT

Remove conductor rails to the drive module; check drive module,
motor power cable, motor and DC bus smoothing choke and replace,
if necessary.
Cause 2: Short-circuit in unit
Replace unit.
P-FAULT
Display dark:
Braking power of drive within permissible range.

P-FAULT
Display flashing:
(Warning)
Bleeder is fully loaded. Braking power of drive may not continue to rise.

P-FAULT
Display red:
Shutdown was triggered because bleeder is overloaded.
Cause 1:

Remedy

(Operating status)

(Fault - stored)

The braking power of the drive is too high

1. Check energy content of the drives.Reduce drive speed or
increase load cycle time.
2. Evaluate bleeder pre-warning contact (BVW contact).
Cause 2: Bleeder defective or internal fault in unit

Remedy

Replace unit.

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6. Troubleshooting

B

A
H3

T- FAULT

H4

U- FAULT

B

A
H3

T- FAULT

H4

U- FAULT

B

A
H3

T- FAULT

H4

U- FAULT

T-FAULT
Display dark:
Heatsink temperature within permissible range.

T-FAULT
Display flashing:
(Warning)
Heatsink temperature too high. Power will be switched off within the next 30
seconds.
T-FAULT
Displayx red:
(Fault - stored)
Shutdown was triggered as heatsink temperature too high.
Cause:

Remedy

B

A
H3

T- FAULT

H4

U- FAULT

B

A
H3

T- FAULT

H4

U- FAULT

Unit overloaded or ambient temperature too high

Check load or ambient temperature. Temperature pre-warning
contact (TVW-Kontakt) of the unit must be evaluated.

U-FAULT
Display dark:
DC bus voltage has exceeded permissible range.

(Operating status)

U-FAULT
Display red
(Fault - stored)
Shutdown was triggered because the DC bus voltage has exceeded maximum
value.
Cause 1:

Remedy

(Operating status)

Mains voltage too high

Check mains voltage (rated value: 3 x 380...480 V AC ± 10 %);
replace unit.
Cause 2: Fault in unit

Remedy

Replace unit.

6.4. Rating plate data
When contacting INDRAMAT Customer Service, please have all the information
on this plate handy.

Production week

Unit type
Part number
basic unit

TVD1.3-08-03
246503

K26/96

SN247368-08751

B26

Barcode

Serial number

Change index

TSTVD1.3

Fig. 6.3: Rating plate of the TVD 1.3

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7. Dimensional data

7.

Dimensional data

max. 2.5 mm2

max. 1.5 mm2

LEDs

max. 2.5 mm2

max. 25 mm2

X 12

7.1. Dimension sheet TDV 1.3 power supply mdule

17

X9

P N

max. 10 mm2

60
82.5

Tightening
torque
of the power
connections

X5

L+

L-

X8

X7

7

30

X4

X3

X2

RESET

52.5

7

X1

S2

9

= M5; MA = 3 Nm

= M5; MA = 3 Nm

L+; L-;

373

MA = tightening torque [Nm]

cooling air inlet

cooling air outlet

390

325

}

P N

8
min. 80 mm

shock protection

355

min. 80 mm
free

free

UL - registered !
Fig. 7.1:

150
MBTVD

Dimension sheet TVD 1.3 power supply module

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7. Dimensional data

7.2. Dimension sheet NAM 1.3 power adapting module
390

11

17

105

52.5

60

7

X1

U1 V1 W1 U2 V2 W2 1L+ 2L+

X7

P N

7

X8

9

cooling air inlet

cooling air outlet

325

373

24.5

shock protection

min. 80 mm free

Tightening torque MA
2 Nm
4 Nm

min. 80 mm
free

355

Cross sec.
10

MBTVD/NAM

UL - registered !

25

3 Nm

Weight
NAM 1.2-08
NAM 1.2-15

approx. 11 kg
approx. 18 kg

Power dissip.

Clamps

90 W

U1/V1/W1/U2/V2/W2
10 mm2

150 W

10 mm2

Fig. 7.2:

1L+/2L+
10 mm2
25 mm2

Dimension sheet of NAM 1.3

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7. Dimensional data

7.3. Dimension sheet CZ 1.2-01-7 bus voltage
capacitor
220
206

52.5
180

P N X8

60

105

7

7

7

Capacitance
CZ 1.2-01-7

1 mF

Nominal voltage
700 V

Weight
approx. 2.5 kg
MBTVD/CZ1101

Fig. 7.3:

Dimension sheet of the CZ 1.2-01-7

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7. Dimensional data

C

7.4. Dimension sheet KD 23/26 commutating chokes

Circuitry:
U1
V1
H

D1
D
A

E
B

Table of dimensions:
Inductance Curr./
Type
A
mH
KD 23
KD 26

0.38
0.38

30
15

V2

W1

F

U2

W2

Oblong hole in
direction " B "

PE

MBKD23/26

Dim. in mm
A

B

C

D

150 90 185 100
120 71 130 75
Fig. 7.4:

D1

E

F

70
-

70
55

6x10
6x8

Clamps
/mm2

H

Weight/
kg

10
4

6,5
2,8

25 M6
- M5

Power
loss/
W
35
28

Dimension sheet of the KD 23/26

7.5. Dimension sheet DC bus smoothing choke
GLD 16/17

Circuitry Smoothing reactor

B

E

G

F

1

X7/1L+
Supply
module
TVD
1

2

X7/2L+
C

D
D1
A

2

X12

Table of Dimensions
Type

Curr./
A

A

MBGLD16/17

B

C

D

D1

E

F

Clamps /
mm 2

G

Weight/
kg

Power
loss / W

GLD 16

25

107 170 120

73

93

114

6x12

15

M5

10

3,5

50

GLD 17

50

135 230 160

83

107

163

8x16

15

M6

35

9

90

Fig. 7.5:

Dimension sheet DC bus smoothing choke GLD 16/17

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7. Dimensional data

7.6. Dimension sheet CZ 1.02 auxiliary capacitance
102

102

4.4 x 7

M4

12
0

min. 165

Drill diagram for
CZ-1.02
44.5

120
MBCZ1.02

Fig. 7.6:

Dimension sheet of the CZ 1.02

min. 80mm free

7.7. Dimension sheet TCM 1.1 aux. capacitance mod.
208
18

7

Cooling air outlet

shock protection

390

355

373

105

L- L+
X15

9

min. 80mm frei

L- L+

7

60

Shown without shock protection

Cooling air inlet

Tightening torque M (Nm) for L-; L+;
A

from Ms 58 : M5 = 2.5 Nm

X15: L-; L+ = power connections max. 6mm

Weight: TCM 1.1-04-W0 approx. 6kg

2

Fig. 7.7:

TCM 1.1-08-W0 approx. 7kg

MBTCM

Dimension sheet of the TCM 1.1

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7. Dimensional data

min. 80mm free

7.8. Dimension sheet TBM aux. bleeder module

18

208
7

cooling air outlet

shock protection

390

355

373

105

L- L+
X15

EB

9

min. 80mm free

L- L+
7

X16

60

cooling air inlet

X15/ L-; L+ = power connections, max. 10 mm2
X15/ EB = control connections, max. 2.5 mm2
X16
= blower power source DC 24V, max. 2.5 mm2

Fig. 7.8:

MBTBM

Dimension sheet of the TBM

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7. Dimensional data

7.9. DST Autotransformers with a secondar or output
voltage of 380...460 V
As a result of the broad input voltage range, the TVD 1.3 can be attached to most internationally used power
systems without the use of a transformer. With mains rated voltages of & lt; 380 V or & gt; 480 V a transformer is
required. The following transformers can be used in conjunction with the TVD 1.3 for rated mains voltage as listed
in column 2 of the table. A special transformer type or transformer connection for each mains voltage is not
required.
The connected load for the TVD 1.3 is dependent upon the voltage. When calculating the connected load take
the output voltage of the mains transformer into account.
Example: mains voltage or transformer inputv oltage = U1 = 525 V, ratio = ü = 1.26

U2 =

U1
525 V
=
= 417 V
ü
1.26
P DC • √(3 x 417 V)

SAN =

25.5

PDC = DC bus cont. power in W

S AN = connectefd load in VA
Type plate: example
GmbH D 97816 Lohr a. M.

C

Type DST 20/S/580 - 480
Prim. 480 … 580 V
Sec. 380 … 460 V
S 20 kVA

YNa0

Bj.

1993

30 … 25 A
T

40/B

f 50/60 Hz

Circuits:
overvoltage

U2

V2

W2

undervoltage

G

E
D
A

U1
N

V1

a

W1

F
B

*
b

*) max. Belastung: DC 24V/1A; AC 230V/1A

Dimensional table:
Type
DST
1)

2)

3)

4/S/240-460
7.5/S/240-460
12.5/S/240-460
25/S/240-460
50/S/240-460
4/S/580-460
7.5/S/580-460
12.5/S/580-460
25/S/580-460
50/S/580-460
4/S/500-460
7.5/S/500-460
12,5/S/500-460
25/S/500-460
50/S/500-460
4/S/690-460
7.5/S/690-460
12.5/S/690-460
25/S/690-460
50/S/690-460

Primary or
input
voltage
(±10%)

Dim. in mm

Weight
kg

Clamps
mm2

Power
dissip.
W

Transmission
ratio

A

B

C

D

E

F



200…240V

240
335
360
480
580

150
175
190
195
265

260
365
395
500
540

170
230
250
356
400

110
160
170
----270

120
145
160
158
215

11
11
11
13
18

24.5
55
70
135
195

10
10
10
35
70

120
225
310
500
750

ü = 0.52

480…580V

240
240
300
360
420

130
140
155
190
215

260
260
325
395
450

170
170
210
250
280

110
110
140
170
190

100
110
125
160
155

11
11
11
11
14

18
22
37
72
95

4
4
10
10
35

140
260
375
625
1000

ü = 1.26

480…500V

180
205
240
300
335

105
130
140
155
175

190
210
260
325
365

125
145
170
210
230

80
95
110
140
160

75
95
110
125
145

7
7
11
11
11

8.5
13
22
36
53

4
4
10
16
35

160
260
440
750
1050

ü = 1.09

570…690V

240
300
335
420
480

140
155
175
205
222

260
325
365
450
500

170
210
230
280
356

110
140
160
190
-----

110
125
145
145
185

11
11
11
14
13

22
37
57
88
178

10
10
10
16
35

140
225
375
500
750

ü = 1.5

MBDSTsteh

1) Nominal power n kVA

2) max. nominal input voltage in V

3) max. nominal output voltage in V

Fig. 7.9: DST autotransformers
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8. Order information

8.

Order information

8.1. Type codes TVD

Example: TVD 1.2 - 15 - 03
Unit abbreviation
TVD = supply module for
direct mains connections
Series
Design
DC bus cont. power
15 = 15 kW
08 = 7.5 kW
Dc bus voltage
03 = 320V
TVD/Typenschl

Fig. 8.1:

Type codes TVD

8.2. Available supply module types of the TVD 1.3 and
accessories
Designation

Available types

1. Supply module

TVD 1.3-08-3
TVD 1.3-15-3

1.1. electrical conn.
accessories

E1-TVD
E2-TVD
E3-TVD

1.2. connector for
blower supply of the
drive modules

socket
part no.: 219 118

2. Auxiliary devices
2.1. Mains supply module

NAM 1.3-08
NAM 1.3-015
for bus conn. see section 8.4.

2.2. Capacitance

CZ 1.2-01-7

2.3. Commutating choke

KD 26
KD 23

part no. 246 544
part no. 246 429

2.4. DC bus
smoothing choke

GLD 16
GLD 17

part no. 242 665
part no. 242 124

3. Aux. bleeder module

TBM 1.2-040-W1/024

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8. Order information

8.3. Overview of electrical connecting accessories
K..
TDA

K..

K..

TVD

TVD

K..

K..

K..
TDA

16polig

16polig

E1 - TVD

E2 - TVD

TDM
TFM
TWM

K..

K..

TVD

TVD

K..

K..

TDM
TFM
TWM

12polig

12polig

E3 - TVD

E3 - TVD
TVD/Zubehör

Fig. 8.2:

Overview of electrical connecting accessories

8.4. Overview of 16-pin bus cable for NAM 1.3

Adjacent units
NAM

TVD

TVD

NAM

IN175/155

IN175/110

units on top of each other
- bus connection on left -

units on top of each other
- bus connection on right -

TVD

TVD

IN178/650

IN182/650

NAM

NAM

Fig. 8.3:

Bus cable overview

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8. Order information

8.5. Item list of mains supply with TVD 1.3
See section 8.2. for available types.

Item

Article

1.0

Supply module TVD 1.3-..-03

1.1

Electrical conn. accessories E.-TVD

2.0

Auxiliary devices
optionally:
mains adapter module NAM 1.3-.. bus conn. cable IN.../...
or
commutation choke KD.. and
capacitance CZ 1.2-01-7 and
DC bus smoothing choke GLD..

3.0

Aux. bleeder module TBM 1.2-040-W1/024

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9. Index

9.

Index

A
Additional bleeder module TBM 25
Additional DC bus capacitanc 24
Ambient Conditions 13
Angular positioning error 42
Arranging the drives 31
Aux. bleeder module 67
Auxiliary contact 38

B
B6 circuit 30
Basic losses 33
Bb1 46
Bb1 contact 8, 38
Bleeder losses 33
Bleeder resistor 26
Blower 27
Bridge capacitance 24
Busbars 23

C
Capacitive leakage currents 30
Charging current limit 10
Choke 10
Commercial pulse-sensitive FI type current limitin
Commutation choke 17, 23
Compact mains adapter 17
Connected load 10
Connecting block X7 19
Control cabinet 31
Control voltage output 12
Current limiting protective devices 30
CZ 1.02 62

30

D
DC bus capacitors 10
DC bus circuit 8, 23, 42
DC bus dynamic braking 36
DC bus smoothing choke 17, 24
Diagnostic dislay 53
DIN 40 050 31
Direct mains connection 19
Drive system monitoring 8
DST Autotransformers 64

E
E-stop 40, 42
E-stop button 38
E-stop chain 42
Earthed three-phase mains 21
Electrical conn. accessories E.-TVD 67
Electrical connecting accessories 66

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9. Index

Electrical Connections 14
Electronics 27
Electronics Power 12
Electronics supply buffer capacitance 28
End plug 29
EPU+ 28
EPU+ and EPU- 28
EPU- 28
Extensive monitoring functions 8
External bleeder resistor 26
External jumper 10
Extreme load capabilities 10

F
False tripping 30
Fault signal 38
FI type current limiting circuit breakers 30
Front view 34
Functional power features 10
Fuse protection 21
Fuse rating 21

G
Gearboxes 42
Generator mode 8
Grounded wye or delta system 21

H
High-voltage link 8

I
Increased ambient temperatures 13
Individual components connected in series 16
Inductance machine 42
Input OFF 44
Input ON 44
Input ZKS 44
Installation elevations 13
Installation requirements 31
Interconnect diagram 15
Internal DC bus dynamic braking 10
IP 10, 31
Isolation transformer 21
Isolation transformers 30
IT mains 21
Item list 67

K
KD 23/26 61

L
" L+ line“ 24
Leakage current 20, 30
Leakage inductance 20

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9. Index

M
Main functions 8
Mains connection to power circuits 19
Mains connection via a transformer 20
Mains failure 28
Mains filter 30
Mains frequency 19
Mains inductance 20
Mains perturbance 17
Mains supply earthing requirements 21
Mains voltage 19
Maximum acceleration rating 11
Maximum fusing 21
Maximum length 23
Maximum number of drives 31
Miniature circut-breaker 27
Monitor circuits 42
Monitoring functions 8

N
NAM 1.3 17, 59, 66, 67
NCB Link 45
NCB link 36, 38, 40, 42
Non-periodic overvoltages 22

O
Order information 65
Output Bb1 46
Output BVW 48
Output K1NC 49
Output K1NO 49
Output TVW 49
Output UD 48
Overload capabilities 10, 11
Overtravel signal 38
Overview of 16-pin 66
Overvoltages 22

P
Periodic overvoltage 22
Permanent magnetic fields 10
Position-control 42
Potential-free contact 10
Power losses 33
Power OK 48
Power range 9
Power ratings 11
Power section 12
Power shutdowns 10
Power stages 10
Power supply to the drives 8

R
" Ready " status 46
Regulated current consumption
Regulated DC bus voltage 10
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70

9. Index

Return movements 42
rf interference supression filters

30

S
Safety clearance 33
Semi-conductor devices 21
Series connected units 17
Service life 10
Servo fault 38
Shielded conductors 30
Signal Voltages 46
Signal voltages 8
Spacing dimensions 32
Storage capacitance 28
Storage capacitor 17
Supply system requirements 19
Supply to electronics and fan 27
Supply to the electronics 8
Switched-mode drive controllers 30
Switching rate 44
System perturbations 24

T
TBM 63
TBM 1.2 25
TBM 1.2-040-W1/024 67
TCM 1.1 62
Terminating plug 29
TVD 1.3 Interconnections 35
TVD 1.3 supply module 7
TVD 1.3 with adapter module NAM 1.3 17
TVD 1.3 with separate series components 18
TVD's diagnostic signals 27
Type codes 65

U
UD contact 42
UD output 28
UL Registered 10
Unearthed three-phase mains
Utilization category gL 21

21

V
Voltage across the resistor
Voltage dips 19
Voltage interrupt 19

26

W
Wire ribbon cable 8
Wire ribbon connection
Wiring diagram 14
Wye point 30

29

X
X1

29

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Indramat