engineering mannesmann Rexroth Supply Module KDV 2.3 Applications DOK-POWER*-KDV*2.
About this documentation Titel Type of documentation: Documenttype Internal file reference Reference This documen2@ation is used: KDV 2.3 Supply module for AC drives Applications DOK-POWER*-KDV*2.3****-ANW1-EN-E1,44 • Mappe 6 • KDV23-AN.pdf • 209-0049-4306-02 This electronic document is based on the hardcopy document with document desig.: DOK-POWER*-KDV*2.3****-ANW1-EN-P • 02.
Table of Contents Table of contents Page 1. INDRAMAT's modular AC drive system 5 1.1. The design of the KDV 2.3 supply module ...................................... 6 2. Applications 2.1. Functional power features of the KDV 2.3 ....................................... 8 2.2. KDV 2.3 power ratings .....................................................................9 2.3 KDV 2.3 - technical data ................................................................ 10 3.
Table of Contents 5. Interface descriptions 5.1. Signal voltages ...............................................................................36 5.2. Ready .............................................................................................36 5.4. Feedback power too high ...............................................................37 5.3. Electronics supply working .............................................................37 5.5. Power supply working .............................
1. INDRAMAT's modular AC drive system 1. INDRAMAT's modular AC drive system The modular INDRAMAT AC drive is made up of the following parts: • control gears, • a supply module, and, • the drive modules, which can be combined with each other components depending upon power or functions wanted. L1 L2 L3 3xAC 50 ... 60Hz Input power Autotransformer Power contactor Supply module (e.g., KDV 2.
1. The design of INDRAMAT's modular AC drive system 1.1. The design of the KDV 2.3 supply module Power supply to the drives The threephase bridge rectifies the threephase mains AC voltage and provides the DC high voltage for the drives. When the drives are in generator-mode, the regenerated energy is absorbed by the bleeder and transformed into heat. The buffer capacitance provides sufficient smoothing. Power supply to the electronics The KDV 2.
2. Applications 2. Applications INDRAMAT's KDV supply modules can be operated with a continuous mechanical output of 24 kW. The continuous regenerative power can equal up to 2 kW. Supply modules with mains regeneration are available for higher continuous regenerative power demands. Input power L1 L2 L3 1) 30 kW KDV 2.3 drive modules 2) 3) 2 kW Pm 1) autotransformer 2) smoothing choke 3) additional capacitance Pm 24 kW FSKDV23 Figure 2.1: Power range of a KDV 2.
2. Applications 2.1. Functional power features of the KDV 2.3 • Simplified fusing Only overload protection for the power supply line is needed. Commercial power protection switches or slow-blow fuses can be used. • Ground fault monitoring of the attached drives In the event of a fault, power is immediately switched off by opening the Bb1 contact and signalled via the optical display on the LED.
2. Applications 2.2. KDV 2.3 power ratings It is possible to optimize usable KDV 2.3 to meet the requirements of an application by combining additional components. (1) (2) (3) (4) (5) (6) (7) (8) Additional components PDC kW PKB-3 kW PKB-03 kW PBD kW PBM kW Wmax kWs Pm kW S kVA 15 30 90 2 40 100 12 16 GLD 13 --- 22 30 90 2 40 100 17,6 23 GLD 12 CZ 1.02 30 30 90 2 40 100 24 32 GLD 12 TCM 1.
2. Applications 2.3 KDV 2.3 - technical data Designation Symbol Unit KDV 2.3-100-220/300-000 Nominal input voltage UACN V 3 x 230V (+10%; -15%) or 3 x 220V (+15%; -10%) Frequency fN Hz 50...60 DC bus voltage UDC V Continuous DC bus voltage Pcont kW 30 (with add. capacitance 4 mF) Peak DC bus power Ppeak kW 90 Continous bleeder power PBD kW 2 Peak bleeder power PBM kW 40 Max.
3. Guidelines for installation and electrical connections 3. Guidelines for installation and electrical connections The following KDV 2.3 terminal diagram is a recommendation of the manufacturer of the unit. The circuit diagrams of the machine builder must be used for installation! • DOK-POWER*-KDV*2.3****-ANW1-EN-E1,44 • 06.
L1 L2 L3 PE 3xAC (50 - 60 Hz) with mains-related earth conductor Q1 T1 • DOK-POWER*-KDV*2.3****-ANW1-EN-E1,44 • 06.
3. Guidelines for installation and electrical connections 3.2. Mains connection - power section Connection voltage Frequency Mains connection via transformer 3 x AC 230 V (+10%; -15%) or 3 x AC 220 V (+15%; -10%) 50 to 60 Hz The mains voltage can generally be adapted by using an autotransformer (also see Section 3.5: "Requirements of the power supply system"). The KDV 2.3 can be directly connected to 3 x AC 220 V - power systems. 3 x AC 50...
3. Guidelines for installation and electrical connections 3.3. Fuse protection for the power connection The KDV 2.3 mains connection can be protected by using either circuit breakers or gL classsification fuses (slow-blow). Using power circuit breakers has the advantage that faulty operation, with two phases, for example, is not possible. The protective device is generally placed on the primary side if a matching transformer is used.
3. Guidelines for installation and electrical connections 3.5. Power supply requirements Grounded threephase mains Voltages can be adapted to grounded mains systems, either star systems with a grounded neutral or a system with a grounded phase (TN or TT mains), by using an autotransformer. The KDV 2.3 can be directly connected to 3 x AC 220 V mains. Ungrounded threephase mains There is the increased danger in ungrounded mains (IT mains) that overvoltages can occur between phases and housing. The KDV 2.
3. Guidelines for installation and electrical connections 3.6. DC bus Use the busbars found in the connection accessories of the drive module to connect the drive modules to the DC bus of the KDV 2.3. Use individual cables with stranded wires for longer connections (maximum length is one meter). smoothing choke TCM L- additional module and PDC < 23 kW 35 mm2 for PDC > 23 kW < 30 kW L- L- L- L+ L+ L+ drive module drive module KDV 2.
3. Guidelines for installation and electrical connections 3.7. Additional capacitance on the DC bus It is possible to connect additional capacitors (CZ 1.02) or additional capacitance modules (TCM) to the DC bus to increase the capacity of the KDV 2.3. Increasing power Energy capacitor for power failures An additional capacitance of 4 mF is needed to utilize this. In a few applications, it might be necessary for the drives to back up in the event of a power failure.
3. Guidelines for installation and electrical connections 3.10. Wire-ribbon connection for the electronics and signal exchange The wire-ribbon connection X1 has two functions: • supplying power to the drive electronics, and, • signal exchange between the supply and drive modules. The wire-ribbon cable is part of the connecting accessories of the drive module.
3. Guidelines for installation and electrical connections 3.11. Fault current protective device Discharge current Capacitive discharge currents always flow to earth in switch-mode drive controllers. The extent of the discharge current is dependent upon: • the number of drive controllers used, • the length of the motor power cable, and, • the ground conditions at installation site.
3. Guidelines for installation and electrical connections 3.13. KDV 2.3 from the front Terminal for smoothing choke X28 X28 a X12 PE busbar L1 Mains terminals X12 a L2 L3 L- Voltage output for D.C.
4xø5 11 351 +1 15 373 ±0,2 • DOK-POWER*-KDV*2.3****-ANW1-EN-E1,44 • 06.97 50 +1 115 = = 18 86 +1 = 2xø11 6xø5 Panel cut-out for outer blower is only required in units with forced cooling. Panel cut-out for KDS, KDV and KDA modules clearance 96 ±0.2 78 ±0.2 92 = clearance View from inside the control cabinet KD. 110 ±0.5 KDV 2. 200 ±0.5 KDA 2. KDA 3. KD. TDM. DDS2. KDV 2. 155 ±0.5 KDA 2. KDA 3. TDM 3. 4. DDS 3 KDA 2. KDA 3. 137 ±0.5 110 ±0.5 KDV 3. 110 ±0.5 KDV 2. KD.
hexagon socket with SW5 Note conductive connections on backwall of control cabinet and mounting frame! • DOK-POWER*-KDV*2.3****-ANW1-EN-E1,44 • 06.97 Cap screw / 4x M4x18Z4-1 DIN912 (1) 5 Finger guard 109-0575-3236-XX (1) Mounting frame for K-module 109-0575-4831-XX (2) Clearance to flammable materials or parts which can be affected by heat: at least 300 mm! Mounting frame for blower 109-0575-4833-XX (1) Those parts labelled with (2) are in of accessories kit M1 - 109-0575-4851-XX. KDV2/Montage.
3. Guidelines for installation and electrical connections Heat loss Heat loss occurs when the KDV 2.3 is operated. This is caused by basic losses during signal voltage generation, power losses and by energy transformation in the bleeder. The heatsink, which conducts this heat loss, is mounted to the back of the KDV 2.3. This means the KDV 2.3 is mounted with the heatsink sticking out of the back of the control cabinet.
4. Control circuits 4. Control circuits (control of input power) The control circuits relate to • switching input power on and off, and, • the E-Stop. The control circuits INDRAMAT recommends illustrate the operating principle. Several different control circuits are suggested in this section. The control scheme selected and its effect depends on the features and timing of the entire machine and is the responsibility of the machine builder. • DOK-POWER*-KDV*2.3****-ANW1-EN-E1,44 • 06.
4. Control circuits 4.1. Differentiating features of the power circuits Bringing the drives to a standstill with faulty drive electronics controlled braking for an E-Stop or a power failure with D.C bus dynamic braking without DC bus dynamic braking by the drive electronics by the NC control unit Figure 4.
4. Control circuits 4.2. Using the DC bus dynamic brake The best way to bring the drives to a standstill with a fault depends on the drive equipment used and the features of the machine. The following recommendations should, therefore, only be viewed as a support for the machine builder. The machine manufacturer is fully responsible for the features and the scope of the individual safety mechanics! The DC bus dynamic brake is intended to protect the machine.
4. Control circuits E-Stop button, light barrier, safety door, step-pad contacts tripped or pendant enable deactivated These monitoring devices serve to protect personnel.
4. Control circuits 4.3. DC bus short-circuiting switch The DC bus short-circuit switch recommended by INDRAMAT is conceived to protect either machine or plant against damage in the event of a drive failure. This can be used to brake motors with permanent magnetic excitation even in the event of drive control failure. This function cannot, however, be the only safety device used to protect personnel. Circuit design This DC bus short-circuit contactor can switch the "short-circuit current" on but not off.
4. Control circuits Switching frequency A maximum of six switching procedures is permitted per minute. The number of possible switching sequences is reduced if the sum of the rotary drive energy and the energy stored in the additional capacitance is greater than 1500 Ws. Otherwise, the DC bus short-circuit resistor will be overloaded.
4. Control circuits 4.4. KDV 2.3 control circuits with dynamic braking Application Modular synchronous motors are used. This control circuit achieves a high degree of safety at low cost. The monitoring capabilities built into the drive system are most effectively implemented. Typical applications: • the KDV 2.3 is only supplying feed drives, and, • if asynchronous main drives and feed drives are being operated by the same KDV 2.3.
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4. Control circuits 4.5. KDV 2.3 control circuits without dynamic braking Application When an uncontrolled coasting of the drives cannot damage the machine. Typical applications: • if the KDV 2.3 supplies only asynchronous drives, and, • if the end position of the feed axis has been sufficiently damped. The DC bus voltage is not short-circuited. Asynchronous drives are not braked by dynamic braking in the presence of a drive fault.
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4. Control circuits 4.6. Control circuits for a controlled braking of the drives for an E-stop or power failure Application For those drives coupled as an electronic drive via the NC control, and which cannot accept a phase-angle error with a power failure or an E-stop. Features The DC bus voltage is not short-circuited. This means that power is available for a controlled braking of the drives.
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5. Interface descriptions 5. Interface descriptions 5.1. Signal voltages Signal voltages The signal voltages can be tapped off of terminal strip X10. These terminals are for measuring and test purposes. If these voltages are used out of the KDV, then make sure that no interference voltages are coupled in (use short, shielded cables). Do not exceed the load capacity of the signal voltage outputs to ensure proper operation of the drives! The ±15 VM are short-circuit-proof.
5. Interface descriptions 5.3. Electronics supply working Output NH Transistor output NH, terminal X10/8 Maximum load DC 24V/100mA Operating status: no power to the electronics fault in auxiliary voltage, DC bus voltage functional auxiliary voltage functional Output high-resistance low-resistance high-resistance external protective circuits X10/4 +24V L KDV 2.3 ϑ R >= 240 Ω NH 5.6 Ω X10/8 0VL SPKDV23NH Figure 5.2: Protective circuit of the NH transistor output 5.4.
5. Interface descriptions 5.5. Power supply working UD contact Output UD, terminal X10/11 - X10/12 Potential-free contact, maximum load DC 24V/1A Operating status: no power to the electronics faulty Output open open power supply functional closed The UD contact acknowledges that the power supply system is working.
5. Interface descriptions This makes it possible for the NC control unit to brake the drives to a standstill with either a mains or phase failure. The power regenerated during braking must be greater than the power consumed. The Bb1 contact always switches the power supply off with a drive fault. The superordinate control must guarantee that the drives are braked with a closed NC bridge because the command-to-zero is dropped.
6. Guidelines on fault clearance 6. Troubleshooting guidelines Lengthy troubleshooting and repair to drive components on the machine are not acceptable because of the resulting production down-time. Thanks to their construction, INDRAMAT AC drives enable individual functional units to be easily and completely replaced without the need for tuning. This means servicing is limited to fault-location either in the motor, the power supply module or the drive in the event of a fault.
6. Guidelines on fault clearance Danger due to voltage in conductive parts There can be dangerous voltages at the following connections: • At all supply module connections and associated transformers, capacitors and additional bleeders. In particular, at the power connections (terminal X9), control voltage input X10, and the blower supply connections X13 and X14. • At the drive modules, motors and the plug-in connectors of the motor.
6. Guidelines on fault clearance 6.2. Diagnostics displays Please note that the messages are only valid if the +24V- and +/-15V control voltages are fault free! The fault messages "bleeder overload" and "ground short" can be cleared by pressing the reset key on the KDV 2.3 (key S2) or by switching off electronics power.
6. Guidelines on fault clearance Auxiliary voltage LED "auxiliary voltage" not lit up (Fault message) Cause 1: Fuse F3 or F4 is defective Remedy Check fuses F3 and F4 and replace, if necessary. Cause 2: Voltage input interrupted. Remedy . Power O.K. Remedy Check the voltage at X10a (230 V AC). LED "power O.K." does not light up (Fault message) Cause 1: Voltage is too low, or a phase on X9 is missing Check mains input at X9 (3 x 220 V AC) Cause 2: DC bus voltage less than 200 V DC Remedy 1.
185 with blower hood FLAT GASKET Weight: KDV 2.3 mount access. M1-D bleeder hood SH-KDV blower LE 3 Max. total weight 7. • DOK-POWER*-KDV*2.3****-ANW1-EN-E1,44 • 06.97 approx. 18 kg approx. 1.7 kg approx. 1.7 kg approx. 2.5 kg approx. 23.9 kg Stud torque (Nm) for connecting bolts 7. Dimensional data Dimensional data 7.1. KDV 2.3 supply module - dimensional data Figure 7.1: Dimensional data for the KDV 2.
7. Dimensional data 7.2. Dimensions: DST 3-phase AC autotransformer A B A Type: B1 G Standing version for foot mount type DST.../S H E F D Example: Rating plate S Bj. DST 2,5/S/380/415/440-220 YNa0 Horizontal version for wall mount type DST.../L Diagram: 1993 220-230V 2,5 kVA H E F D K C Prim.: 380-400/415/440 V Sec.
7. Dimensional data 7.3. Dimensions: DLT 3-phase AC isolation transformer A C1 B1 G1 B A Hø E F D G C Hø E F D Standing version for foot mount type DLT.../S Example: rating plate Type: Diagram: Bj. DLT 2,5/S/380/415/440-220 1993 Prim.: 380-400/415/440 V Sec.: 220-230V S 2,5 kVA Horizontal version for wall mount type DLT...
7. Dimensional data 7.4. Dimensional data: CZ 1.02 additional capacitor 102 102 4.4 x 7 M4 12 0 min. 165 Drill holes for mounting CZ-1.02 44.5 120 MBCZ1.02 Figure 7.4: Dimensional data for the CZ 1.02 additional capacitor min. clearance 80 mm 7.5. Dimensional data: TCM 1.1 add. capacitor module 18 208 7 air outlet safety guard 390 355 373 105 L- L+ L- L+ 9 min.
7. Dimensional data 7.6. Dimensional data: GLD 12/13 smoothing choke electrical connection 1 2 C M6x20 H∅ E F B A H∅ H∅ oblong hole in direction "J" I J 1.1 2.1 1.2 2.2 1 2 inner schematic diagram Type mH/A B A dimensions in mm C F H∅ E I J max. conn. diameter Gewicht weight kg power loss W 100 GLD 12 1.0/100 160 121 285 60 100 7x14 97 121 35mm 2 12 13.5 GLD 13 1.0/50 60 6x10 66 16mm 2 4,6 4.8 122 90 225 -- 82 50 MBGLD12/13 Figure 7.
7. Dimensional data 7.7. Dynamic brake contactor Alternating current device: = • 220V AC 50/60Hz contactor LC1-D25008 MA • 110V AC 50/60Hz contactor LC1-D25008 F7 • auxiliary block LA1-DN22 • overvoltage limiter LA4 DA 1U (RC link) • bridge for diameter up to 25 mm2 (Telemecanique, part no. LA 9-D 2561) 44 = safety clearance 84 87 (D.1) 87 (D.2) LA4 10 93 126 (LA1) 56 = Direct current device 44 = safety clearance 87 (D.1) 87 (D.
8. Order details 8. Order details 8.1. KDV type codes Example: KDV 2.3 - 100 - 220 / 300 - 000 Product name KDV Series 2 Version 3 Rated current 100 = 100A Nominal voltage for power electronics 220 = AC 220V DC bus nominal voltage 300 = DC 300V Nominal voltage for heatsink blower; AC 115 or 230V, 50 to 60 Hz (depends on blower type = 000) Figure 8.1: KDV type keys 8.2. Available versions Designation Available version supply module KDV 2.
8. Order details 8.3. Summary of the electrical connecting accessories K.. K.. K.. KDV 2.3 KDV 2.3 K.. K.. K.. 16 pin 16 pin E10-KDV E11-KDV T.. DDS K.. K.. KDV 2.3 KDV 2.3 K.. K.. T.. DDS 12 pin 12 pin E12-KDV E12-KDV KDV/Zubehör Figure 8.3: Summary of electrical connecting accessories 8.4. Order details for mains supply with KDV 2.3 Item Article 1.0 supply module KDV 2.3 - 100 - 220 / 300 - 000 1.1 mechanical mounting accessories M1-KD 1.
9. List of INDRAMAT service reps 9. List of INDRAMAT service reps 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 Chemnitz: Indramat GmbH c/o Rexroth Vertriebs- und Servicegesellschaft mbH Beckerstraße 31 09120 Chemnitz Tel 03 71/355-0 Telefax 03 71/355-230 ENGLAND G.L. Rexroth Ltd.
9. List of INDRAMAT service reps 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.
10. Index 10. Index A Additional capacitance 17 Additional capacitance on the D.C. bus Additional capacitor 9 Additional components required 9 Applications 7 Autotransformer 13 Auxiliary voltage 43 17 B Bb1 contact 36 Bb1contact does not open or close Bleeder overload 42 Bleeder warning contact 37 Blower power supply 17 Busbars 16 BVW contact 37 43 C Circuit breakers 14 Connecting accessories 51 Connection voltage 13 Continuous bleeder power 9 Continuous D.C.
10. Index F F2 43 F3 43 F4 43 F6 43 Fault current protective device 19 Feedback power too high 37 FI-current limiting type circuit breakers 19 Functional power features of the KDV 2.3 8 Fuse protection for the power connection 14 Fuses 43 G Gear cutting machines 25 GLD 12 9 GLD 13 9 Grounded threephase mains 15 Guidelines for protecting personnel 40 H Heat loss 23 Heatsink 23 I INDRAMAT AC drive system 5 INDRAMAT service reps 52 Installing the KDV 2.3 21 K KDV 2.3 - data 10 KDV 2.
10. Index P Peak bleeder power 9 Permissible overvoltage levels 15 Power O.K. 43 Power circuit breaker 14 Power connection 14 Power ratings 9 Power supply in order 38 Protection against accidental contact 16 S Safety guidelines 40 Selecting the mains contactor 14 Signal voltages 36 Smoothing choke 9 Switching input power on and off 24 T TCM 1.
Indramat
