REXRTOH DDS02.1/03.1 Digital AC Servo Drive

REXRTOH DIAX02 DDS02.1/03.1 Driver Controller: Professional Project Planning and Deep Technical Analysis

In the fields of modern industrial automation, machine tools, textiles, printing, packaging, and robotics, high-performance and high reliability servo drive systems are the core source of power. The DIAX02 series DDS02.1 and DDS03.1 drive controllers launched by INDRAMAT (now under Bosch Rexroth) represent the mature application of its modular digital AC servo drive technology. This article will be based on the official project planning manual, and provide a detailed application guide for engineering and technical personnel by thoroughly analyzing the system architecture, safety specifications, technical characteristics, installation planning, and electrical integration points of this series of controllers.

System Overview and Modular Architecture

The DDS (Digital Drive System) drive controller adopts a highly modular design, aiming to flexibly combine multiple AC servos and spindle drives through a single power supply unit to form a compact drive unit. The system core consists of the driver controller basic unit, software modules, plug-in modules, and firmware, achieving hardware and functional configurability.

Basic Unit: As the core carrier of the driver controller, it provides power interfaces, control logic, and basic cooling architecture. The slots (U1-U5) are initially empty, and corresponding modules need to be assembled according to functional requirements.

Software module: located in slot U5, embedded firmware and driver parameters. It is not only the carrier of functional implementation, but also ensures the portability of parameters during device replacement. The type code on it (such as DSM02.1-FW) identifies the firmware version and feature set.

Plugin module: inserted into the U1-U4 slots of the base unit, greatly expanding the interface and functionality of the controller. Mainly includes:

SERCOS interface (DSS01.1/01.3): Supports digital communication with compatible control systems through fiber optics.

Analog Interface (DAA01.1): Provides an analog command interface with traditional control systems and integrates incremental or absolute encoder simulation functions.

Single axis positioning module (DLC01.1/02.1): Upgrades the drive controller to an independent programmable single axis positioning unit, supporting up to 3000 program blocks.

Input/output interface (DEA04.1/05.1/06.1, etc.): Provides a channel for exchanging digital signals with PLC.

Other specialized interfaces, such as Interbus-S slave interface (DBS02.1/02.2), high-resolution position interface (DEF01.1), gear encoder interface (DZF01.1/02.1), etc., meet specific application requirements.

Firmware: defines all functional characteristics of the driver controller. Firmware is ordered independently to ensure version consistency and traceability. The firmware configuration clearly displays the firmware versions of each module in the entire controller through the nameplate identification on the front panel.

Safety Guidelines: Core Guidelines for Ensuring Personnel and Equipment Safety

The manual extensively emphasizes the importance of safe operation, as any negligence can lead to property damage, personal injury, and even fatal danger.

Electrical Safety

High voltage risk: Exposed parts with operating voltage exceeding 50V are extremely dangerous. Before operation, the power must be disconnected and wait for at least 5 minutes (due to internal capacitor discharge), while ensuring that the device is not accidentally restarted. All units and motors must be reliably grounded at the grounding point.

High discharge current: Leakage current may exceed 3.5mA. All units must be permanently connected to the protective grounding of the power supply system to prevent the casing from being charged.

Protection against low voltage: Signal voltage (5-30V) circuits belong to safety isolation circuits (protection against low voltage), but still require standardized operation.

Preventing dangerous activities:

Incorrect speed commands, software malfunctions, hardware problems, wiring errors, encoder malfunctions, etc. can all cause unpredictable dangerous movements.

We cannot rely solely on the built-in monitoring function of the driver to ensure the safety of operators. Superior monitoring devices or measures must be installed on the equipment side, such as guardrails, cover plates, light curtains, etc., and comprehensive hazard and error analysis must be conducted.

The emergency stop switch must be installed in a location that is easily accessible to the operator, and its function must be verified before starting.

Before entering the danger zone, it is necessary to confirm that the drive has completely stopped.

Installation and handling protection: It is necessary to prevent risks of compression, shearing, cutting, and collision. Use appropriate tools and equipment, wear necessary personal protective equipment (such as goggles, safety shoes, gloves), and ensure a clean work area.

Technical data and selection considerations

Power section:

DC bus voltage: nominal 300V (± 15%).

Current capability: The numbers in the controller model (such as DDS02.1-W050-...) represent peak current, while the sustained current depends on the selected motor and the "overload factor". The manual provides a detailed correspondence table between peak current and continuous current, which is a key basis for motor/controller matching and selection.

Signal processing current consumption: The power supply unit provides+24V DC and ± 15V DC power to all connected drive controllers. The total current consumption shall not exceed the output capacity of the power supply unit. The current consumption consists of three parts: the basic unit, the plug-in module, and the motor feedback. The manual provides detailed tables of current consumption for each part, which facilitates system power supply design and calculation.

Environmental conditions:

Allowable ambient temperature under rated data: 0 ° C to+45 ° C.

The maximum temperature under derating data is+55 ° C.

Storage and transportation temperature: -30 ° C to+85 ° C.

Maximum installation altitude (rated data): 1000 meters.

Protection level: IP20.

When the ambient temperature or altitude exceeds the standard, the continuous torque and short-term torque of the motor need to be reduced according to the chart.

Drive controller energy consumption: The actual energy consumption of the controller depends on the static current (I_IN) of the connected motor. The manual provides energy loss curves for the DDS02.1-W (hot technology), DDS02.1-A (cold technology), DDS02.1-F (liquid cooling), and DDS03.1-W series, which are used to calculate the heat generation and heat dissipation requirements inside the control cabinet.

Cooling method:

Thermal technology (W series): Heat is dissipated inside the control cabinet. Installation is simple, but it may require forced ventilation or air conditioning cooling of the control cabinet.

Cold technology (A series): By using external heat sinks and fans, most of the heat is dissipated outside the control cabinet, making it suitable for cabinets with limited space.

Liquid cooling (F series): Through the circulation of coolant for heat dissipation, it has extremely high efficiency and can recover some waste heat.

Motor feedback type: The basic unit is divided into two types, which only support digital servo feedback (DSF, suffix '- D') or rotary transformer feedback (RSF, suffix '- R'). When selecting, it is necessary to ensure that the motor and controller feedback type codes match.

Control cabinet planning and mechanical installation

Layout principle: The drive controller and its power unit are designed to be installed in a control cabinet or enclosed enclosure (protection level IP10). It is recommended to place high output, high current drivers as close as possible to the power supply unit to reduce line impedance and interference.

Installation spacing: The manual provides detailed installation dimension diagrams and clearance requirements between adjacent units to ensure sufficient heat dissipation space and maintenance channels, which must be strictly followed.

Key installation points for different models:

DDS02.1-W...: Installed inside a standard cabinet, pay attention to heat dissipation.

DDS02.1-A...: Using cold technology, the heat sink part extends outside the cabinet. During installation, it is necessary to use installation panels and sealing rings to ensure that the cabinet opening is sealed. External fans can be installed on adjacent units.

DDS02.1-F...: Liquid cooling model, requires matching coolant pipeline connection kit (such as SH-FL, M2-F), and strictly follows the installation specifications of the liquid cooling system.

DDS03.1-W...: The structure is more compact, and the installation method is similar to DDS02.1-W.

EMC and interference suppression: In order to comply with EMC directives (such as 89/336/EWG), it is necessary to follow the "EMC in Drive and Control Systems" project planning manual. Measures include: separate laying of power lines and signal lines, use of shielded wires and single ended grounding for analog signals, use of shielded cables or shielded routing for motor power cables, installation of recommended interference filters in the main power lines, etc.

The use of heat exchangers: If a heat exchanger is used, it must be installed and set correctly to prevent condensation water from damaging the components inside the cabinet. The cabinet should be well sealed, with a set temperature not lower than 40 ° C, and it should still be operated for a period of time after shutdown to balance the temperature inside and outside the cabinet and prevent condensation. The installation position should ensure that condensed water does not drip or splash onto electrical components.

Detailed explanation of electrical connections

General principles: Emphasize the separation of signal lines and power lines, easy replacement of connectors, proper handling of shielding, and human body electrostatic discharge.

Basic unit connection (taking DDS02.1 as an example):

① Chassis grounding: Use a wire with a cross-sectional area not less than the power cord and at least 10mm ² to connect to the grounding bar of the power unit.

② ③ ④ Motor power cable: It is recommended to use INDRAMAT original cable (including three-phase wire, protective ground wire, shielded motor temperature control and brake wire), with a maximum length of 75 meters. Pay attention to the line sequence identification when connecting.

④ Connector X6: Used for motor brake (external 24V DC power supply) and motor temperature monitoring (PTC).

⑤ DC bus connection: Adjacent drivers are usually connected through the DC bus bar in the accessory kit. For high current models (150A, 200A), bus bars must be used.

⑥ Connector X1 (bus connection): Used to connect the power supply and communication flat cable of control electronic devices, starting from the power unit in series, and the end unit needs to be plugged into the terminal plug.

⑦ Connector X3: Includes "Ready" contact (Bb, indicating that the controller can be powered on), drive latch control input (AS+/AS -) and response contact (ASQ/ASQ), two analog diagnostic outputs (AK1, AK2).

⑧ Connector X2 (RS232): Used for debugging and parameter setting through service cable IKS0391 (mainly for analog interface configuration).

⑨ Connector X4 (motor feedback): Connect the corresponding DSF or RSF feedback cable depending on whether the controller is of the '- D' or '- R' type. The scale feedback of linear motors (LAF/LAR) is not connected here, but to the corresponding plug-in module.

⑩ Connectors X13, X14a, X14b: only available for DDS02.1-A models, used to connect external cooling fans (LE4 type).

Plugin module connection: The terminal diagram and technical data of each plugin module should refer to the independent "DIAX02 Plugin Module" document.

Accessories, Power on and Maintenance

Accessory kit: includes electrical connection kit (E. - DDS 2 for DDS02, E. - DDS 3 for DDS03), connector kit (S. - DDS 2, depending on specific configuration), service cable, fiber optic cable (for SERCOS), mechanical accessories (such as fan LE4, installation panel, liquid cooled connection kit), etc., greatly facilitating system integration.

Power on through charging resistor: When using TVM 2.1/2.4 or KDV 1.3 power supply units and meeting specific conditions (such as large transformer capacity), a charging resistor power on scheme is required. The manual provides corresponding control circuit diagrams. Special note: The "Bb" contact of DDS drivers has a different meaning from old-fashioned analog drivers (TDM/KDS). It only closes when the control voltage is turned on and all monitoring functions are normal, and cannot be used as a signal for bypass charging resistors.

Status recognition and storage transportation: The product packaging is labeled with barcode tags to indicate the content. There is a nameplate on the front panel of the equipment. Storage and transportation should be carried out in a dry, dust-free, and shock resistant environment with a temperature range of -30 ° C to+85 ° C.

Model Supplement

1、 Driver controller model

1. DDS02.1 series (basic model)

DDS02.1-W015-... (Thermal Technology Cooling)

DDS02.1-W025-... (Thermal Technology Cooling)

DDS02.1-W050-... (Thermal Technology Cooling)

DDS02.1-W100-... (Thermal Technology Cooling)

DDS02.1-W150-... (Thermal Technology Cooling)

DDS02.1-W200-... (Thermal Technology Cooling)

DDS02.1-A050-... (Cold Technology Cooling)

DDS02.1-A100-... (Cold Technology Cooling)

DDS02.1-A150-... (Cold Technology Cooling)

DDS02.1-A200-... (Cold Technology Cooling)

DDS02.1-F050-... (liquid cooling)

DDS02.1-F100-... (liquid cooling)

DDS02.1-F150-... (liquid cooling)

DDS02.1-F200-... (liquid cooling)

2. DDS03.1 series (basic model)

DDS03.1-W030-... (Thermal Technology Cooling)

DDS03.1-W050-... (Thermal Technology Cooling)

Instructions:

Suffix - .. Represents possible other variant codes, such as feedback type (- D or - R).

The letters in the model indicate the cooling method: W=hot technology, A=cold technology, F=liquid cooling.

The number in the model (such as 050) represents the peak current (unit: ampere).

2、 Software module/firmware model

DSM02.1-FW (Standard Software Module)

FWA-DIAX02-SSE-02VRS-MS (firmware model example)

FWC-DIAX02-SSE-02VRS-MS (firmware model example)

3、 Plug in module model

1. Communication interface module

DSS01.1 (SERCOS interface)

DSS01.3 (SERCOS interface)

DAA01.1 (analog interface with incremental/absolute encoder simulation)

DBS02.1 (Interbus S Slave Interface)

DBS02.2 (Interbus S slave interface, used to connect to DLC02.1)

DBS03.1-FW (Interbus S Slave Interface Firmware)

DAK01.1 (ARCNET coupler card, used for CLC command card)

2. Positioning and motion control module

DLC01.1 (single axis positioning module)

DLC02.1 (single axis positioning module with Interbus-S interface)

DLC02.2-FW (Single axis positioning module firmware)

CLC-D02.1A-FW (Command Card, for "Electronic Axis")

CLC-D02.2A-FW (Command Card)

3. Input/output module

DEA04.1 (I/O interface, 15 in/16 out)

DEA04.2 (I/O interface)

DEA051 (I/O interface)

DEA05.2 (I/O interface)

DEA06.1 (I/O interface)

4. Position feedback interface module

DEF01.1 (incremental position interface)

DEF02.1 (incremental position interface)

DFF01.1 (high-resolution position interface, sine signal)

DZF01.1 (gear encoder interface)

DZF02.1 (gear encoder interface)

DRF01.1 (Rotary Transformer Interface)

DLF01.1 (linear ruler interface)

DPF02.1 (unclear, suspected to be related to position feedback)

DPF03.1 (unclear, suspected to be related to position feedback)

DPF05.1-FW (position feedback related firmware)

DSE01.1 (Sum Input Interface)

5. Other/Unclear Classification Modules

DAE01.1

DSSC01.1-FW

DSSC01.3-FW

DSSC02.1

DSSC03.1-FW

4、 Motor and feedback type code

1. Motor series

MDD (Digital Servo Motor)

MKD (Synchronous Servo Motor)

LAR (linear motor with casing)

LAF (Linear Motor)

2. Feedback type (in the motor model suffix)

DSF: Digital servo feedback (corresponding to controller suffix - D)

-L-xxxx

-S-xxxx

-M-xxxx (with multi turn absolute value encoder)

-T-xxxx (with multi turn absolute value encoder)

RSF: Rotary Transformer Feedback (corresponding to controller suffix - R)

-G-xxxx

-K-xxxx (absolute value encoder with pulse generator)

5、 Power unit model

TVM 1.2

TVM 2.1

TVM 2.4

KDV 1.3

KDV 2.2

KDV 2.3

KDV 3.1

KDV 4.1

TVD 1.2

TDA (possibly power related)

KDA3.2 (possibly related to power supply)

TVR3 (possibly power related)

KVR 1 (possibly related to power supply)

6、 Attachment and Cable Kit Model

1. Electrical connection kit

E. - DDS 2 (for DDS02 controller connection)

E. - DDS 3 (for DDS03 controller connection)

S. - DDS 2 (connector kit, selected according to configuration, such as S1-DDS 2, S8-DDS 2, etc., with dozens of variants listed in the document)

2. Mechanical accessories

LE4 220 (fan unit, 220V AC)

LE4 115 (fan unit, 115V AC)

M1-KD (mechanical installation accessories for DDS02.1-A)

SH-FL (DDS02.1-F Liquid Cooling Accessory Kit)

M2-F (DDS02.1-F Liquid Cooling Pipeline Connection Kit)

3. Cable

IKS0391 (service cable for RS232 debugging)

IN 253 (specific motor power cable, color coded)