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Mannesmann Rexroth DDS 2.1 Applications Manual

Digital intelligent ac servo drives with analog interface
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DATASHEET
INDRAMAT
DEA 5.1
OTHER SYMBOLS:
DEA51, DEA5 1, DEA5.1, DEA 51, DEA 5 1, DEA 5.1
RGB ELEKTRONIKA AGACIAK CIACIEK
SPÓŁKA JAWNA
Jana Dlugosza 2-6 Street
51-162 Wrocław
Poland
biuro@rgbelektronika.pl
+48 71 325 15 05
www.rgbautomatyka.pl
www.rgbelektronika.pl
www.rgbelektronika.pl
www.rgbautomatyka.pl

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  • Page 1 DATASHEET INDRAMAT DEA 5.1 OTHER SYMBOLS: DEA51, DEA5 1, DEA5.1, DEA 51, DEA 5 1, DEA 5.1 RGB ELEKTRONIKA AGACIAK CIACIEK SPÓŁKA JAWNA Jana Dlugosza 2-6 Street 51-162 Wrocław www.rgbelektronika.pl Poland biuro@rgbelektronika.pl +48 71 325 15 05 www.rgbautomatyka.pl www.rgbautomatyka.pl www.rgbelektronika.pl...
  • Page 2 YOUR PARTNER IN MAINTENANCE Repair this product with RGB ELEKTRONIKA ORDER A DIAGNOSIS LINEAR ENCODERS SYSTEMS INDUSTRIAL COMPUTERS ENCODERS CONTROLS SERVO AMPLIFIERS MOTORS MACHINES OUR SERVICES POWER SUPPLIERS OPERATOR SERVO PANELS DRIVERS At our premises in Wrocław, we have a fully equipped servicing facility. Here we perform all the repair works and test each later sold unit.
  • Page 3 Rexroth DDS 2.1 and MDD Digital Intelligent AC Servo Drives with ANALOG interface Application Manual DOK-DIAX02-DDS02.1*ANA-ANW1-EN-P Indramat 257182...
  • Page 4 • DOK-DIAX02-DDS02.1*ANA-ANW1-EN-E1,44 • 12.96...
  • Page 5 Section About this documentation ____________________________________________________________________ Contents ____________________________________________________________________ The digital intelligent AC servo drive ___________________________________________________________________ The digital intelligent AC servo drive with ANALOG interface ____________________________________________________________________ Fundamental safety notes ____________________________________________________________________ Commissioning equipment ____________________________________________________________________ Operating the drive controller during commissioning and diagnostics ____________________________________________________________________ Commissioning procedure up to initial start-up of the AC servo drive ____________________________________________________________________ Commissioning the functions of the digital AC servo drive...
  • Page 6 • DOK-DIAX02-DDS02.1*ANA-ANW1-EN-E1,44 • 12.96...
  • Page 7 About this documentation Titel DDS 2.1 and MDD Digital intelligent AC servo drives with ANALOG interface Type of documentation: Applications Manual Documenttype DOK-DIAX02-DDS02.1*ANA-ANW1-EN-E1,44 Internal file reference • Mappe 11b • DDS*A-AN.pdf • 209-0069-4315-03 Reference This electronic document is based on the hardcopy document with document desig.: 209-0069-4315-03 EN/12.93...
  • Page 8 AC servo drives Doc. No.: 71801 with SERCOS interface Doc. No.: 71800 Dimensioning Selecting functions DDS 2 and MDD DDS 2.1 and MDD Digital intelligent Digital intelligent AC servo drives AC servo drives DDS2.1 and MDD DDS and MDD Dimensioning manual System configuration manual –...
  • Page 9 About this documentation Digital intelligent AC servo drives Digital Digital AC servo motors Digital AC servo drive System presentation Ac servo mtors Overview – Benefits of digit. int. AC servo drives – power steps – preferred fields of application – dimensions –...
  • Page 10 • DOK-DIAX02-DDS02.1*ANA-ANW1-EN-E1,44 • 12.96...

  • Page 11: Table Of Contents

    Table of Contents Table of Contents Page 1. The digital intelligent AC servo drive 2. The digital intelligent AC servo drive with ANALOG interface 2.1. Components of the digital AC servo drive ........ 15 2.2. Function schematic of the digital AC servo drive ..... 16 2.3.
  • Page 12 11.1.Repair Card ................109 11.2.Specific axis data list, to be completed by hand ....110 11.3.Example of a parameter file printout ........112 11.4.DDS 2.1 drive controller connection diagram for motors with resolver feedback .......... 114 11.5.DDS 2.1 drive controller connection diagram for motors with digital servo feedback ........

  • Page 13: The Digital Intelligent Ac Servo Drive

    1. The digital intelligent AC servo drive Digital intelligent AC servo drives are microprocessor-controlled brushless 1. The digital intelli- three-phase AC drives with outstanding servo control characteristics in gent AC servo drive terms of dynamic response and precision. Excellent performance data, flexible operating modes and applications- orientated functions offer the ideal pre-requisites for: –...
  • Page 14 1. The digital intelligent AC servo drive SERCOS interface The SERCOS interface is a serial real-time communication system between NC controls and drives which has been proposed for standardi- zation in a draft standard (DIN IEC/TC 44) drawn up by a joint workgroup made up of representatives from the Verein Deutscher Werkzeug- fabriken e.V.
  • Page 15 1. The digital intelligent AC servo drive ANALOG interface DDS 2.1 Series drive controllers with ANALOG interface allow digital intelligent AC servo drives to be operated by conventional NC controls with a ±10V analog interface. The possible operating modes are: –...

  • Page 16: The Digital Intelligent Ac Servo Drive With Analog Interface

    3 x AC (380 to 460) V, (50-60) Hz. A digital intelligent AC servo drive consists in each case of a carefully matched combination of AC servo motor MDD and a DDS 2.1 drive controller. Mains...

  • Page 17: Components Of The Digital Ac Servo Drive

    2.1. Components of the Figure 5 shows the designations of the various components making up digital AC servo drive a digital AC servo drive with a DDS 2.1 drive controller and an MDD digital AC servo motor. Electrical connection accessories...

  • Page 18: Function Schematic Of The Digital Ac Servo Drive

    2. The digital intelligent AC servo drive with ANALOG interface 2.2. Function schematic of The interaction of an NC control with an analog command output and the the digital AC servo drive digital AC servo drive with ANALOG interface is illustrated in Figure 6. Digital NC control Digital intelligent drive controller...

  • Page 19: System Configuration Of The Digital Ac Servo Drive

    This configured controller and the digital AC servo motor MDD are then combined into proven and readily available system configurations. (Fig. 11 to 14). Drive controller, basic unit Transparent (protective) cover SYSTEMCONFIGURATION DDS 2.1-W050-DS01-00 DDS 2.1 DDS 2.1-W050-D DSM 2.1-S11-01.RS DSS 1.1 COVER COVER...
  • Page 20 2. The digital intelligent AC servo drive with ANALOG interface Distinguishing criteria The digital AC servo drive with ANALOG interface is distinguished of the digital according to: AC servo drive 1. Type of position actual-value evaluation – incremental – absolute 2.
  • Page 21 2. The digital intelligent AC servo drive with ANALOG interface Configuration rating plate SYSTEM CONFIGURATION DDS 2.1-W050-DA01-00 DDS 2.1-W050-D DSM 2.1-S11-01.RS DAE 1.1 COVER COVER COVER Abb.8.1InbetrDDS Fig. 9: Rating place of the configured drive controller Type code of the...
  • Page 22 Drive controller / basic unit DDS 2.1- ..-R 2 Configuration rating plate (sticker) TYS-DDS 2.1 - ..- RA01 - 00 Software module DSM 2.1-E11-01.RS ANALOG interface with incremental encoder emulator DAE 1.1...
  • Page 23 Drive controller / basic unit DDS 2.1- ..-R Configuration rating plate (sticker) TYS-DDS 2.1 - ..- RA02 - 00 Software module DSM 2.1-A11-01.RS ANALOG interface with absolute encoder emulator DAA 1.1...

  • Page 24: System Configuration Components

    (U5) Motor power connection (X5) Status display, alarm and fault messages (H1) DC link circuit connection (X5) Control voltage DDS 2.1-W•••-D connection (X1) Rating plate RS-232 interface for VT 100 terminal or PC (X2) Analog Slot for I/Os (X3)
  • Page 25 2. The digital intelligent AC servo drive with ANALOG interface Rating plate Type designation Drive controller Basic unit Shipment DDS 2.1-W025-D date Article 247203 K42/92 SN247203-01073 Bar code Status as-delivered Serial number Fig. 16: Rating plate of a drive controller, basic unit The rating plate is located on the front panel of the basic unit (Fig.
  • Page 26 ENA3A-Abb10/InbetrDDS Fig. 18: Designations of ANALOG interface module features The ANALOG interface of the DDS 2.1 drive controller serves to communicate with an NC control equipped with a ±10V analog interface. The ANALOG interface has therefore been provided with various control inputs and signal outputs (see Fig.
  • Page 27 2. The digital intelligent AC servo drive with ANALOG interface Type code Command communication Example: D S S 1 . 1 module 1. Designation Digital ANALOG interface with absolute encoder emulator ..= DAA Digital ANALOG interface with incremental encoder emulator .. = DAE Digital SERCOS interface............
  • Page 28 2. The digital intelligent AC servo drive with ANALOG interface Software module Bar code Software version Serial number DSM 2.1 DSM 2.1-E11-01RS Abbreviated type code Type code of the software module ENA3A-Abb12/InbetrDDS Fig. 21: Designations of software module features Matching of the drive controller to the motor and of the AC servo drive to the machine mechanics is done by means of parameters stored in the software module.
  • Page 29 2. The digital intelligent AC servo drive with ANALOG interface Rating plate Software module DSM 2.1-E11-01.RS Fig. 22: Rating plate, software module Type code Software module Example: D S M 2 . 1 - S 1 1 - 0 1 . R S 1.
  • Page 30 2. The digital intelligent AC servo drive with ANALOG interface Digital AC servo motors MDD... digital AC servo motors are supplied in the following feedback versions. – Motors with "digital servo feedback" (DSF) – Motors with "digital servo feedback and multi-turn encoder" (DSF + MTG) –...
  • Page 31 2. The digital intelligent AC servo drive with ANALOG interface Type code AC servo motors Example: MDD 112B-N-015-N2L-130GB0/S000 1. Designation 2. Motor frame size 3. Motor overall length 4. Frame design 5. Rated speed– 1500 rpm 6. Vibration severity 7. Motor version 8.
  • Page 32 2. The digital intelligent AC servo drive with ANALOG interface Rating plate MDD servo motors Build Date S.No. Com.No. Part No. natural convection surface cooled I.Cl. Tcont Nm/A Brake 24 V +- 10 % Made in Germany INDRAMAT-Logo Build date Week and year of manufacture Motor type S.No.

  • Page 33: Warning Notes And Symbols

    3. Fundamental safety notes 3. Fundamental safety notes This Application Manual contains the following warning notes and 3.1. Warning notes symbols: and symbols Symbol Meaning Explanation Danger: Instructions or DOs and DON’Ts for the prevention of accidents and damage to equipment. Note: Text passages marked with this symbol contain special notes...

  • Page 34: Safety Notes For Commissioning

    3. Fundamental safety notes 3.3. Safety notes When commissioning a servo drive problems may arise that increase the for commissioning risk of accidents and damage to the drive and machine. These are: – errors in wiring up the motor, drive controller and feedback –...
  • Page 35 3. Fundamental safety notes ENA3A-Abb15/InbetrDDS Fig. 28: Power supply module and DDS 2.1 drive controller with screwed-down transparent protective plates. Accident risk through lethal voltage levels! Never operate drive controllers without the transparent protec- tive plate in place (see. Fig. 28). All connections on terminal block X5 carry lethal voltage levels when power is switched on.

  • Page 36: Notes On Protection Of Equipment

    3. Fundamental safety notes 3.5. Notes on protection of equipment Risk of damage INDRAMAT electronic drive components are provided with comprehen- through wrong connection sive protective circuitry and protected against overloading. Nevertheless, the following precautions must still be taken: – Voltage levels applied to inputs must always be in accordance with prescribed data.

  • Page 37: Measuring Instruments

    4. Commissioning equipment The following equipment is needed for commissioning: 4. Commissioning equipment – measuring instruments – battery power source – service cable IN 391 – personal computer with a program emulating a VT 100 terminal or a VT 100 terminal itself –...

  • Page 38: Battery Power Source

    H1: Starting lockout (drive interlock open) indicator (AH) H2: Controller enable indicator (RF) H3: Overtemperature warning indicator (TVW) +24V±10% External ENA3A-Abb18/InbetrDDS power supply Fig. 30: Proposed circuitry for connecting up a battery power source to the DDS 2.1 with ANALOG interface • DOK-DIAX02-DDS02.1*ANA-ANW1-EN-E1,44 • 12.96...

  • Page 39: Service Cable In 391

    IN 391 / 2 Lengths in m ENA3A-Abb19/InbetrDDS (2, 5, 10, 15) Fig. 31: Connecting up a personal computer via RS 232 interface to a DDS 2.1 with ANALOG interface 4.4. Personal computer (PC) The PC must fulfil the following conditions: –...

  • Page 40: Vt 100 Terminal

    4.5. VT 100 Terminal The VT 100 terminal is the minimum hardware requirement for visualiza- tion and operation of the user interface stored in the DDS 2.1. The VT 100 terminal cannot be used for electronic storage of data outside the DDS 2.1 as it has no memory capacity.

  • Page 41: How To Handle The Parametrizing And Diagnostics Program

    5. Operating the drive controller during commissioning and diagnostics Pre-conditions: 5. Operating the drive controller dur- – DDS 2.1 drive controller installed, electrical connections made and tested (see Section 6). ing commissioning and diagnostics – AC servo motor power and feedback cables connected up to the drive controller.
  • Page 42 5. Operating the drive controller during commissioning and diagnostics Drive status The "DRIVE STATUS" menu supplies instantaneous information on: – the signal status of control inputs and signal outputs used on the installed ANALOG interface module, as given below: - Overtemperature warning - Controller enable - Drive enable Ired1...
  • Page 43 5. Operating the drive controller during commissioning and diagnostics PROGRAM PROGRAM START Enter MAIN MENU LANGUAGE DRIVE STATUS SELECTION Safety note "Drive Parametrization" LOAD OPERATION HELP PARAMETERS MODES PARAMETERS TEXT SCALING POSITION TORQUE AMPLIFIER GAIN ERROR SAVE EVALUATION REDUCTION AND MOTOR PARAMETERS REACTION PARAMETERS...
  • Page 44 5. Operating the drive controller during commissioning and diagnostics Absolute encoder error Fig. 33: Absolute encoder error Program start (screen message) Fig. 34: Program start (screen message) Main menu Fig. 35: Main menu • DOK-DIAX02-DDS02.1*ANA-ANW1-EN-E1,44 • 12.96...
  • Page 45 5. Operating the drive controller during commissioning and diagnostics Drive status Fig. 36: "DRIVE STATUS" menu Language selection Fig. 37: "LANGUAGE SELECTION" menu Safety note "Drive Parametrization" Fig. 38: Safety note to "PARAMETERS" menu • DOK-DIAX02-DDS02.1*ANA-ANW1-EN-E1,44 • 12.96...
  • Page 46 5. Operating the drive controller during commissioning and diagnostics Parameter menu Fig. 39: "PARAMETER" menu of parametrization and diagnostic program Operating modes, scaling Feedback versions with DSF or RSF Fig. 40: "OPERATING MODES, SCALING" menu Operating modes, scaling Feedback versions with DSF or RSF Help text Fig.
  • Page 47 5. Operating the drive controller during commissioning and diagnostics Operating modes, scaling Feedback versions with absolute encoder options (DSF + MTG or RSF + IDG) Fig. 42: "OPERATING MODES, SCALING" menu for motors with absolute encoders Operating modes, scaling Feedback versions with absolute encoder options (DSF + MTG or RSF + IDG)
  • Page 48 5. Operating the drive controller during commissioning and diagnostics Incremental encoder setup Help text Fig. 45: Help text to "INCREMENTAL ENCODER SETUP" menu Absolute encoder setup Fig. 46: "ABSOLUTE ENCODER SETUP" menu Absolute encoder setup Help text Fig. 47: Help text to "ABSOLUTE ENCODER SETUP" menu •...
  • Page 49 5. Operating the drive controller during commissioning and diagnostics Modulo parameters Fig. 48: "MODULO PARAMETERS" menu Modulo parameters Help text Fig. 49: Help text to "MODULO PARAMETERS" menu Error reaction Fig. 50: "ERROR REACTION" menu • DOK-DIAX02-DDS02.1*ANA-ANW1-EN-E1,44 • 12.96...
  • Page 50 5. Operating the drive controller during commissioning and diagnostics Torque/current limits Fig. 51: "TORQUE / CURRENT LIMITS" menu Torque/current limits Help text Fig. 52: Help text to "TORQUE/CURRENT LIMITS" menu Gain parameters Fig. 53: "GAIN PARAMETERS" menu • DOK-DIAX02-DDS02.1*ANA-ANW1-EN-E1,44 • 12.96...
  • Page 51 5. Operating the drive controller during commissioning and diagnostics Gain parameters Help text Fig. 54: Help text to "GAIN PARAMETERS" menu Amplifier/motor parameters Fig. 55: "AMPLIFIER /MOTOR PARAMETERS" menu Save parameters Fig. 56: "SAVE PARAMETERS" menu • DOK-DIAX02-DDS02.1*ANA-ANW1-EN-E1,44 • 12.96...
  • Page 52 5. Operating the drive controller during commissioning and diagnostics Load parameters Fig. 57: "LOAD PARAMETERS" menu • DOK-DIAX02-DDS02.1*ANA-ANW1-EN-E1,44 • 12.96...

  • Page 53: Saving Data

    3. Set the emulation program to the receive mode (download). 4. Enter a file name for the parameters to be saved. 5. Press button S1 on the DDS 2.1. This starts data transfer. 6. Complete the data transfer after the last "$" character (see the user manual for the emulation program).

  • Page 54: Checks To Be Run With Power Disconnected

    The data on the configuration rating plate must correspond to the components installed in the drive controller. If this is not the case, the AC servo drive and the machine mechanics may be destroyed or damaged! SYSTEMCONFIGURATION DDS 2.1-W050-DA01-00 DDS 2.1-W050-D DSM 2.1-E11-01.RS DAE 1.1 COVER...
  • Page 55 6. Commissioning procedure up to initial start-up of the AC servo drive Wiring Check all wiring for short circuits, interruptions, reverse polarity and conductor cross-sections. Earth connections – Earth the components exactly as prescribed in the specific INDRAMAT connection diagrams. –...
  • Page 56 6. Commissioning procedure up to initial start-up of the AC servo drive Power Digital supply module AC servo drive End connector ATTENTION! ATTENTION! NEVER REMOVE OR INSTALL THIS NEVER REMOVE OR INSTALL THIS PLUGS WHILE VOLTAGE IS APPLIED. PLUGS WHILE VOLTAGE IS APPLIED. BLACK CABLE ON THE BOTTOM! BLACK CABLE ON THE BOTTOM! Verbindung nie unter Spannung...

  • Page 57: Checks To Be Run With Control Voltage Applied

    6. Commissioning procedure up to initial start-up of the AC servo drive 6.2. Checks to be run Before running the following checks, switch on the signal conditioning with control voltage applied voltage supply at the power supply module. The power supply module provides the voltage for signal conditioning in the drive controller.

  • Page 58: Powering Up

    6. Commissioning procedure up to initial start-up of the AC servo drive Set command value Procedure: parameters 1. Set the "maximum command value for maximum velocity" to the maximum output voltage of the battery power source (e.g. 10V). 2. Set the "velocity at maximum command value" to the same value as "bipolar velocity limit value".

  • Page 59: Initial Start-Up Of The Drive With A Battery Power Source

    6. Commissioning procedure up to initial start-up of the AC servo drive 6.6. Initial start-up of the The servo axis can be operated independently of an NC control using a drive with a battery power battery power source (see Section 4.2). source This may be useful in the following cases: –...

  • Page 60: Error Reaction

    7. Commissioning the functions of the digital AC servo drive 7. Commissioning the functions of the AC servo drive with ANALOG interface Digital intelligent AC servo drives offer the possibility of preselecting 7.1. Error reaction different error reactions for each drive in a drive package. Error reactions 1 and 2 make it possible to complete machining operations on workpieces even in the event of errors occurring in other drive package axes not involved in the machining process (e.g.
  • Page 61 – "Ready" contact Bb X3-6/7 on drive controller open (Section 7.4) Fig. 60: Setting error reactions on the DDS 2.1 Irrespective of the selected error reaction, the corresponding error can be evaluated immediately by means of the lag detec- tion feature on an NC control as well as by observing the Bb contact (X3 pin 6/7) on the drive controller (see Section 7.4).
  • Page 62 7. Commissioning the functions of the digital AC servo drive Error reaction and The reaction of the holding brake under different preset error reactions holding brake control is shown in Fig. 61. Error Speed command value 0 Motor torque Holding brake closes n<10 rpm n>10 rpm...

  • Page 63: Safety Lockout (Drive Interlock Open)

    It provides safe shutdown of separate working areas in a machine or a plant. Series DDS 2.1 drive controllers are equipped with a safety lockout to stop a servo axis starting up accidentally. When this lockout is activated, the control electronics for the power output stage are disconnected from the latter by means of a relay contact.
  • Page 64 - potential-free feedback contact 24V, 1A ENA3A-Abb17.6/InbetrDDS 3) Control contact for power electronics Fig. 62: Control inputs and signal outputs of the safety lockout on a DDS 2.1 drive controller Status When the safety lockout has been activated, the status indicator H1 on diagnosis the drive controller will display the message "AS".
  • Page 65 7. Commissioning the functions of the digital AC servo drive Additional information Application examples explaining how to use the safety lockout are contained in the documentation "Safety lockout for DDS 2 drive control- lers" (Doc. No. 209-0069-4313). Time sequence for safety lockout activation NC-stop: operation completed Speed command Drive stopped n(com.) = 0...

  • Page 66: Holding Brake Function

    7. Commissioning the functions of the digital AC servo drive 7.3. Holding brake func- When stopped, servo axes must be secured against involuntary start-up tion if such a movement could cause injury to personnel or damage to machinery. INDRAMAT provides protection of this type in the form of an optional holding brake.
  • Page 67 7. Commissioning the functions of the digital AC servo drive External controller enable via NC control Speed command value = 0 Motor torque Holding brake closes n<10 rpm n>10 rpm Time axis t/ ms The holding brake closes when the motor speed falls below 10 rpm. The holding brake closes after 400 ms when the speed is >...
  • Page 68 7. Commissioning the functions of the digital AC servo drive Holding brake, In cases where the controller enable signal cannot be set and it is manual release necessary to move the servo axis by hand, the holding brake can be released as described below.

  • Page 69: Operational Status (Ready)

    7.4. Operational status In order to avoid unnecessary down time, machinery and plant require (Ready) continuous monitoring. The DDS 2.1 drive controller caters to this need with a signal contact. The potential-free signal contact "Bb" (Ready) on connector X3 pin 6/7 makes it possible to pinpoint the affected machine in the event of a drive error in the associated NC control or signalling device (see Fig.

  • Page 70: Temperature Monitoring

    7. Commissioning the functions of the digital AC servo drive Status diagnoses Status diagnoses are signals referring to the operational readiness of the drive. They are displayed on the status indicator H1. "Ready" When the control voltage has been applied and the drive is free of errors, drive ready the status indicator "H1"...
  • Page 71 Conductors for motor temperature monitoring Conductors for powering the holding brake Shield 5 or white 6 or brown 7 or red 0V B 8 or black 0V B DDS 2.1-W•••-D X13 / 15 signal output Ired1 Ired2 +24V±10% External power source Connector designation may vary accoring to the installed ANALOG interface (see Fig.

  • Page 72: Velocity Command Matching

    7. Commissioning the functions of the digital AC servo drive 7.6. Velocity command Different makes of NC controls are provided with different output voltage matching levels for rapid traverse velocities. INDRAMAT AC servo drives therefore offer the option of adapting the level of the velocity command value. The actual motor speed and direction of rotation depends on the plant design.
  • Page 73 NC control X13 / 15 NC control Differential amplifier Ired1 Ired2 +24V±10% External power source Interface designation depends on the installed ANALOG interface (see Fig. 18) ENA3A-Abb65.9/InbetrDDS Fig. 70: ANALOG interface on the DDS 2.1 drive controller • DOK-DIAX02-DDS02.1*ANA-ANW1-EN-E1,44 • 12.96...

  • Page 74: Command Value Smoothing

    7. Commissioning the functions of the digital AC servo drive 7.7. Command value When the servo drive is controlled in closed loop by the NC control, smoothing stepped command value signals - due to the control’s cycle time - will result in torque fluctuations.
  • Page 75 7. Commissioning the functions of the digital AC servo drive 360° electrical = one cycle TTL square-wave pulses when looking on the motor shaft, clockwise rotation (see Project Planning Manual, Doc.No. 209-0069-4317) Marker pulse DDS 2.1-W•••-D Incremental encoder interface NC control Position interface ext. white ext. brown ext.
  • Page 76 7. Commissioning the functions of the digital AC servo drive 60 [s/min] * 504000 [lines/sec] 20000 line count [lines/rev.] 18000 16000 14000 12000 10000 8000 max. output frequency: 504 kHz 6000 permissible range 4000 2000 2000 4000 6000 8000 10000 Motor speed [ rpm] ENA3A-Abb44/InbetrDDS...
  • Page 77 7. Commissioning the functions of the digital AC servo drive Checking the To check the entry you have just made, execute a homing cycle at marker pulse offset approx. 10% the rapid traverse velocity. If the homing cycle finishes without errors, increase the homing cycle velocity step by step.

  • Page 78: Actual-Position Sensing By Indirect Absolute Position Measuring System

    7. Commissioning the functions of the digital AC servo drive An NC control requires position measuring systems to sense the axis 7.9. Actual-position position on machine axes. These position measuring systems can either sensing by indirect abso- be mounted directly on the machine’s mechanical construction (direct lute position measuring system position measuring system) or on the motor (indirect position measuring...
  • Page 79 The absolute position is output through the ANALOG interface with absolute encoder emulator DAA 1.1 via connector X16 and in SSI data format (refer to Digital intelligent AC servo drives, Project Planning Manual, Doc. No. 209-0069-4317-0019: DDS 2.1-W•••-D NC control Absolute encoder interface (SSI data format)
  • Page 80 7. Commissioning the functions of the digital AC servo drive Setting the The reference position is set using the parameter "absolute encoder reference position parameter" in the „POSITION EVALUATION“ menu. Example (see Fig. 75): – The desired reference position is in the middle of the operating stroke Procedure: 1.
  • Page 81 7. Commissioning the functions of the digital AC servo drive Counting direction of the To match the servo axis traversing direction to the counting direction in position actual value output the machine’s coordinates system, the counting direction of the position actual value output can be fixed by means of parameters.

  • Page 82: Master/Slave Mode

    7. Commissioning the functions of the digital AC servo drive 7.10. Master/slave Machine axes that cannot achieve the required torque with one servo mode drive alone are equipped with two drives working according to the master/slave principle. The master drive controls the velocity for both the positively locked drives.
  • Page 83 7. Commissioning the functions of the digital AC servo drive Checking the 1. Call up the "OPERATING MODES, SCALING" menu (see Section 5). master slave drive 2. Set the current command value output to channel 2 (see Section 9.5) 3. Record the current command value of master and slave at the terminals AK2 on connector X3.3 and X3.4 respectively.

  • Page 84: Torque Reduction

    Depending on the type of machine and its design, certain operating conditions may call for torque reduction of the drive. The DDS 2.1 drive controller allows you to set three different torque reductions. These are selected and activated by binary coded signals through the control inputs Ired1 and Ired2.
  • Page 85 = 20 Nm max desired reduction calculation The installed motor/drive controller combination is: MDD112B.-N-030 DDS 2.1-050 Mains power supply with stabilized DC link circuit. Procedure: 1. For the above motor/controller combination, the following figures can be found in the selection data list: –...
  • Page 86 7. Commissioning the functions of the digital AC servo drive Activating the Selecting and activating the torque/current limit 1 is done by applying +24 torque reduction V DC from an external source to inputs Ired1 and Ired2 (Fig. 81). X13 / 15 NC control +24V Ired1...

  • Page 87: Drift-Free Positioning Of A Servo Axis

    The DDS 2.1 with ANALOG interface as a command communication module allows drift-free positioning of the axis in the "velocity loop" mode after the axis has been stopped.

  • Page 88: Velocity Loop

    7. Commissioning the functions of the digital AC servo drive 7.13. Velocity Loop Matching of the digital servo drive to the machine mechanics is done by activating the velocity loop parameters stored in the motor feedback (see Section 6.3 "Setting the gain parameters". These are the standard parameters for the servo drive.
  • Page 89 7. Commissioning the functions of the digital AC servo drive Velocity loop This parameter sets the proportional gain of the velocity loop. proportional gain "Kpw" Velocity loop derivative/ This parameter sets the derivative/differential gain of the velocity loop. proportional gain "K "...

  • Page 90: What To Do In The Event Of A Power Failure Or Emergency Shutdown

    7. Commissioning the functions of the digital AC servo drive Current loop This parameter defines the proportional gain of the current loop proportional gain This value is motor-specific, set by INDRAMAT and may not be changed. 7.14. What to do in the In the event of a power failure or an emergency shutdown, machines and event of a power failure workpieces risk being damaged by uncontrolled deceleration of servo...

  • Page 91: Setting The Short-Time Operation Torque "M

    7. Commissioning the functions of the digital AC servo drive 7.15. Setting the short- The short-time operation torque M is entered in the parameter "over- time operation torque load factor". Consult the selection data list Doc. No. 209.0069.4302-00 "M " IDE for the value corresponding to the installed motor/controller combi- nation.

  • Page 92: Preparations For Running The Axis With An Nc Control System

    NC control system NC control Position loop Command Vcom. Deviation Vcom. = Kv • Xd AC motor DDS 2.1 controller Feedback Velocity loop Rotor position -Vact. Machine slide Micropro- cessor +Vcom.

  • Page 93: Compensating The Servo Axis Drift

    2. Disconnect the battery power source. 3. Connect up the command conductor and controller enable from the NC control to the servo drive module. 4. Set the velocity command evaluation on the DDS 2.1. (see Section 7.6, Velocity command) 8.2. Compensating...

  • Page 94: Checking The Servo Drive

    8. Final commissioning work 8.3. Checking the servo drive Setting the safety limit switch Set the safety limit switch of the axis at an adequate distance from the fixed stop: Procedure: 1. Check that the cams are of sufficient length. 2.
  • Page 95 E-STOP function. This must happen without the power supply module cutting out with error message "bleeder overload" or the DDS 2.1 with error message 25 "overvoltage". Continuous energy recovery: Run the axes of the drive package to be checked for at least 15 minutes in the load cycle for which the highest energy recovery (braking energy) is to be expected.

  • Page 96: Saving Data

    8. Final commissioning work 8.4. Saving data The "specific axis data list" is intended as an additional data saving option for axis-related parameter contents and should be stored in the machine Saving data using file. This list is to be completed by commissioning personnel on initial the "specific axis data list"...

  • Page 97: Diagnosing The Operating Status Of The Controller Using Its Status Display

    H1" (see Fig. 15). If errors are detected during the initialization phase of the microprocessor in the drive controller, the 7-segment display of the DDS 2.1 with ANALOG interface will indicate the most recent error. The user program will output a list of all initializing errors which have occurred. Initializing errors carry the error codes: 83, 84, 87, 88, 89, 91 (see Section 9.3).

  • Page 98: Status Indications During Drive Initialization

    9. Diagnostics and fault clearance "Drive halt" Meaning: The drive has been stopped at the torque chosen in the menu "TORQUE/ CURRENT LIMIT" and remains in velocity loop mode. Diagnosis text: Drive halt Danger ! If the "drive halt" function is deactivated (by applying 24 V) while the controller enable signal is still applied, the drive will immediately follow the applied command signal.

  • Page 99: Fault Diagnostics And Clearance Using The Drive Controller Status Display

    9. Diagnostics and fault clearance 9.3. Fault diagnostics and The prerequisites for fault diagnosis using the DDS 2.1 drive controller are: clearance using the drive – Mains power is switched on. controller status display The fault message must be reset once the associated fault has been cleared.
  • Page 100 9. Diagnostics and fault clearance "Motor encoder error" The signals emitted by the motor encoder are monitored. If the signals lie outside the tolerance window, this message will be signalled and the main power cut out. Cause: – Defective or disconnected encoder cable –...
  • Page 101 9. Diagnostics and fault clearance Remedy: 1. Check the NC control logics for activating the drive. 2. Remedy the malfunction in the power supply unit. "External power supply voltage error" Different optional plug-in modules have DC-decoupled inputs and out- puts. An external power supply must be applied for proper operation of these inputs and outputs.
  • Page 102 9. Diagnostics and fault clearance "Bridge fuse" The current in the power transistor bridge has risen to more than twice the unit’s rated current. The drive torque function is immediately disa- bled. Cause: 1. Short-circuit in the motor cable 2. Power section of the drive controller defective. Remedy: 1.
  • Page 103 9. Diagnostics and fault clearance ± " 15 V fault" The controller has detected a fault in the ± 15 V supply. Cause: 1. Defective control voltage bus cable 2. Defective supply module Remedy: 1. Check and, if necessary, replace the control voltage bus cable or plug connector.
  • Page 104 9. Diagnostics and fault clearance "Absolute encoder error" (Position outside the monitoring window) 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.
  • Page 105 9. Diagnostics and fault clearance "Drive data invalid" Cause: EEPROM not written or contains invalid data. Remedy: Rewrite the EEPROM. Consult INDRAMAT Service Department. "Parameter data invalid" During the controller initialization phase, one or more parameters in the software module were found to be invalid. Cause: 1.

  • Page 106: Input Errors And Faults Due To Errors While Saving

    2. Replace motor. 9.4. Input errors and faults Faults of this type can only occur in the DDS 2.1 when working with a PC or a VT 100 terminal, and they are indicated by messages on the operator due to errors while saving interface.

  • Page 107: Selecting Signals For Diagnostics Outputs

    Switch off the input for the safety lockout, X3 pin 8/9, and start again. (see Section 7.2) The DDS 2.1 is equipped with two analog diagnostics outputs. These 9.5. Selecting signals may be used to emit internal drive variables for test purposes.
  • Page 108 9. Diagnostics and fault clearance ENA3A-Abb52/InbetrDDS Fig. 87: Analog output signals on the DDS 2.1 • DOK-DIAX02-DDS02.1*ANA-ANW1-EN-E1,44 • 12.96...

  • Page 109: Notes On Component Replacement

    The diagnostics display and the message signals on the DDS 2.1 drive controller enable methodical and effective fault location. Simple replacement of defective drive components guarantees the fastest possible clearance of the fault and resumption of operation without any lengthy assembly and readjustment work.
  • Page 110 10. Overview of parameters 10. Overview of parameters Application parameters Description Unit Operating mode 1= torque / 2 = velocity loop Bipolar velocity limit value [rpm] Overload factor Maximum command value for maximum velocity [V] Velocity at maximum command value [rpm] Command value smoothing filter time constant [ms]...

  • Page 111: Repair Card

    11. Appendix 11. Appendix 11.1. Repair Card Repair Card for INDRAMAT equipment and components Completed by: Company/Town: Date: When replacing single components, Supply job no.: enter component designation Shipment date: if necessary - Machine manufacturer/Company: Type: Machine no.: commissioning date Fault in axis no.

  • Page 112: Specific Axis Data List, To Be Completed By Hand

    Machine manufacturer :............Plant No. :............Machine Type :............Axis designation :............Axis equipment Drive controller :DDS 2.1..........Software module :DSM 2.1-..........MDD servo motor :MDD ..........Supply module :............Date :......Approved by :........Completed by :........Company :........
  • Page 113 11. Appendix 1. Application parameters Recorded value Unit Description Operating mode (1=torque loop/2=velocity loop) Bipolar velocity limit value [rpm] Overload factor Maximum command value for maximum velocity Velocity at maximum command value [rpm] Command value smoothing filter time constant [ms] Line count of the incremental encoder Marker pulse offset [dgr]...

  • Page 114: Example Of A Parameter File Printout

    : XY-AG Plant No. : 1234 Machine Type : Machining center Axis designation : X axis Drive controller : DDS 2.1-W025-D MDD servo motor : MDD065A-N-040 Software module : DSM 2.21-E11-01.03 (16.10.92) OPERATING MODES, SCALING S-0-0032 Operating mode - - - S-0-0091 Bipolar velocity limit value : 2500.0000 rpm...
  • Page 115 11. Appendix • DOK-DIAX02-DDS02.1*ANA-ANW1-EN-E1,44 • 12.96...

  • Page 116: Dds 2.1 Drive Controller Connection Diagram For Motors With Resolver Feedback

    11. Appendix 11.4. DDS 2.1 drive controller connec- tion diagram for motors with resolver feedback ENA3A-Abb90/InbetrDDS Fig. 92: Connection diagram for DDS 2.1-...-R— drive controller for motors with resolver feedback. • DOK-DIAX02-DDS02.1*ANA-ANW1-EN-E1,44 • 12.96...

  • Page 117: Dds 2.1 Drive Controller Connection Diagram For Motors With Digital Servo Feedback

    11. Appendix 11.5. DDS 2.1 drive controller connection diagram for motors with digital servo feedback ENA3A-Abb91/InbetrDDS Fig. 93: Connection diagram for DDS 2.1-...-R— drive controller for motors with digital feedback. • DOK-DIAX02-DDS02.1*ANA-ANW1-EN-E1,44 • 12.96...

  • Page 118: Pin Allocations/Abbreviations On Drive Controller

    0V test voltage X4/4 Signal conductor X4/7 Signal conductor X4/8 Signal conductor X4/9 Signal conductor X4/10 Signal conductor X4/12 Signal conductor X4/14 Signal conductor X4/15 Fig. 97: Connections of the digital servo feedback on the DDS 2.1 • DOK-DIAX02-DDS02.1*ANA-ANW1-EN-E1,44 • 12.96...
  • Page 119 Signal conductor X4/12 X4/13 not used X4/14 X4/15 not used Fig. 98: Connections of the resolver feedback on the DDS 2.1 Plug-in terminal strip X5 Signal Meaning Phase 1 motor connection X5/1 Phase 2 motor connection X5/2 Phase 3 motor connection...
  • Page 120 11. Appendix Plug-in terminal X13, X14 Signal Meaning Analog input 1 (-10V) X13/1 E1 NEGIN Analog input 2 (+10V) X13/2 E2 POSIN Overtemperature warning X13/3 Controller enable X13/4 Drive halt X13/5 Current reduction 1 X13/6 Ired1 (torque reduction 1) Current reduction 2 X13/7 Ired2 (torque reduction 2)
  • Page 121 11. Appendix Plug-in terminal X13, X14 Signal Meaning Analog input 1 (-10V) X15/1 E1 NEGIN Analog input 2 (+10V) X15/2 E2 POSIN Overtemperature warning X15/3 Controller enable X15/4 Drive halt X15/5 Current reduction 1 X15/6 Ired1 (Torque reduction 1) (Torque reduction 2) X15/7 Ired2 External +24V operating voltage...

  • Page 122: Overview Of Indramat Companies, Subsidiaries And Agencies

    Mannesmann Rexroth München: Technisches Büro Indramat ˇ ˇ Indramat GmbH Medvescak 82 c/o Mannesmann Rexroth GmbH YU - 41 000 Zagreb Technisches Büro 041/43 52 27 u. 27 28 26 Institutstraße 14 Telefax 041/43 56 76 D - 8000 München 60...
  • Page 123 División Indramat F.R. OF YUGOSLAVIA Jolastokieta (Herrera) (SERBIA - MONTENEGRO) Apartado 11 37 San Sebastian, 20 017 Mannesmann Rexroth 043/40 01 63 Technisches Büro Indramat Telex 36 172 Gospodar Jevremova BR 1 Telefax 043/39 93 95 YU - 11 000 Beograd (Serbien) 011/630 047 u.
  • Page 124 11. Appendix ARGENTINA HONGKONG AITI - INDRAMAT Mannesmann Rexroth S.A.I.C G.L. Rexroth Ltd. Service - Büro Division Indramat 19 Cheung Shun Street Ul. Pjatnizkaja 46 Acassusso 48 41/7 1st Floor, Cheung Sha Wan, 10 90 17 Moskau (Rußland) 1605 Munro (Buenos Aires)
  • Page 125 11. Appendix THAILAND N. R. Automation Co., Ltd. 49/23-24 Srinakarin Road, Bangna, Prakanong Bangkok 102 60 / Thailand 399 09 20-1; 399 09 56-8 Telefax 662-399 03 06 AUSTRALIA Australasian Machine Tool Co. Pty. Ltd. 9 Webber Parade, East Keilor (Melbourne) Victoria, 30 33, Australia 03/336 78 22 Telefax 03/336 17 52...
  • Page 126 12. Glossary 12. Glossary, Explanations Absolute encoder Absolute value encoder, multiturn encoder, absolute position encoder Position encoders which supply a position signal referred to a reference point set at initial start-up as soon as the power supply is switched on. No reference run necessary during operation.
  • Page 127 12. Glossary Velocity control loop Speed control loop Drive operating mode with SERCOS and ANALOG interfaces in which the drive sets the motor speed or the velocity of the moved machine part with a high dynamic response as a function of the applied velocity command.
  • Page 128 12. Glossary Position control loop Loop to control a system’s position. Multiturn absolute encoder, MTG Multiturn encoder Absolute position measurement over several revolutions. Digital AC servo motors may optionally be fitted with multiturn encoders (absolute measurement of the rotor position over 4092 revolutions). Fan unit Surface cooling Forced cooling with an external fan (optional)
  • Page 129 12. Glossary Servo feedback Special measuring device on servo motors to detect the rotor position and measure the rotor speed (cyclically absolute position sensing). Microprocessor Signal conditioner A microprocessor that achieves a high signal processing speed due to parallel signal conditioning. Singleturn absolute encoder Singleturn encoder Position encoder that supplies an absolute position information signal...
  • Page 130 13. Index 13. Index Absolute encoder emulation Additional plug-in module ANALOG interface 13, 24 Bus connecting cable Command communication module 17, 24 Configuration rating plate 52, 17 Control voltage bus connection Current loop proportional gain DC link circuit connection (X5) Direction of rotation, servo motor Earthing Electrostatic charges...
  • Page 131 13. List of keywords Safety limit switch Separate-source voltage-withstand test SERCOS interface Smoothing time constant Software module 17, 26 SSI interface Status indicator (H1) System configuration Terminal setup Torque arm Torque fluctuations Torque reduction Type code, additional plug-in modules Type code, command communication module Type code, configured drive controller Type code, drive controller, basic unit Type code, MDD servo motors...
  • Page 132 Indramat...

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