Manual Rexroth

engineering
mannesmann
Rexroth
DIAX04
HDD and HDS
Drive Controllers 1st Generation
Project Planning
DOK-DIAX04-HDD+HDS****-PRJ2-EN-P
274944 Indramat
LSA Control S.L. www.lsa-control.com [email protected] (+34) 960 62 43 01
About this documentation HDD and HDS Drive Controllers 1st Generation
Titel DIAX04 HDD and HDS Drive Controllers 1st Generation
Type of documentation Project Planning
Document type code DOK-DIAX04-HDD+HDS****-PRJ2-EN-P
Internal file reference • 209-0074-4304-02
The purpose of this This documentation serves

documentation
• to develop the electro-construction
• to assist in mounting the drive controller into the control cabinet
• to assist in the installation of the drive package
Änderungsverlauf Document designation of previous Status Comments

editions
DOK-DIAX04-HDD+HDS****-PRJ1-EN-P 11.96 first release
DOK-DIAX04-HDD+HDS****-PRJ1-EN-P 05.97 error correction
DOK-DIAX04-HDD+HDS****-PRJ2-EN-P 07.98 revision
(serial interface)
Copyright  INDRAMAT GmbH, 1998

Copying this document and giving it to others, and the use and
communication of the contents hereof, are forbidden. Offenders are liable
for the payment of damages. All rights reserved in the event of a patent or
the registration of a utility model or design (DIN 34-1).
Validity All rights are reserved with respect to the content of this documentation
and the availability of the product.
Published by INDRAMAT GmbH • Bgm.-Dr.-Nebel-Str. 2 • D-97816 Lohr a. Main

Telefon 09352/40-0 • Tx 689421 • Fax 09352/40-4885
Dept. ECD (RS/JR)
Note This document is printed on chlorine-free bleached paper.
HDD and HDS Drive Controllers 1st Generation Contents I
Contents
1 Introducing the System 1-1
1.1 Drive Package - DIAX04 ...................................................................................................................... 1-1
1.2 The individual components of the digital DIAX04 drive........................................................................ 1-2
1.3 Supply units.......................................................................................................................................... 1-2
2 Drive controllers HDD / HDS 2-1

2.1 Configured drive controller ................................................................................................................... 2-1
2.2 Drive controller, basic unit.................................................................................................................... 2-2
2.3 Command communication module ...................................................................................................... 2-2
2.4 Software module .................................................................................................................................. 2-2
2.5 Additional plugin module ...................................................................................................................... 2-2
2.6 Configuration type plate ....................................................................................................................... 2-4
2.7 Type codes of the configured drive controller ...................................................................................... 2-5
2.8 Technical data - an overview ............................................................................................................... 2-7
3 Planning the control cabinet 3-1

3.1 Ambient conditions and Installation elevation ...................................................................................... 3-1
3.2 The use of coolers in the control cabinet ............................................................................................. 3-2
3.3 Dimensional sheets.............................................................................................................................. 3-5
3.4 Connection lines................................................................................................................................. 3-10
3.5 Measures against interference sources in the control cabinet........................................................... 3-11
4 Planning the electrical connections 4-1

4.1 General information ............................................................................................................................. 4-1
4.2 Connecting the basic unit..................................................................................................................... 4-2
5 Accessories 5-1
5.1 LWLs (Fiber optic cables) .................................................................................................................... 5-1
6 Transport and Storage 6-1

6.1 General instructions ............................................................................................................................. 6-1
7 Identifying the Merchandise 7-1

7.1 Delivery slip and barcode sticker ......................................................................................................... 7-1
7.2 Type plate of the drive controller.......................................................................................................... 7-2
7.3 Other type plates.................................................................................................................................. 7-2
8 Mounting and installation 8-1
II Contents HDD and HDS Drive Controllers 1st Generation
8.1 Mounting the drive controller................................................................................................................ 8-1

8.2 Installation ............................................................................................................................................ 8-3
9 Service and Testing 9-1

9.1 Error diagnoses.................................................................................................................................... 9-1
9.2 Repairs and replacements ................................................................................................................... 9-1
9.3 High voltage check and insulation check ............................................................................................. 9-2
10 Index 10-1
Customer Service Locations
HDD and HDS Drive Controllers 1st Generation Introducing the System 1-1
1 Introducing the System
1.1 Drive Package - DIAX04
Fig. 1-1: Digital intelligent drive sytem - DIAX04
The modular concept of the DIAX04 INDRAMAT drive enables a flexible

combination of AC drives to create compact drive packages implementing
but one supply unit.
Together with MKD, MHD, 1MB and 2AD AC motors, HDD and HDS
drives are rapid-response drives, suitable as servo and main drives,
capable of being used in such tasks as machine tools, textile, printing and
packaging machines, or in robotics and handling machines.
1-2 Introducing the System HDD and HDS Drive Controllers 1st Generation
1.2 The individual components of the digital DIAX04 drive
plugin modules
configuration
type plates
X1
L+
L-
contact guard A1
A2 configured
A3
HDS / HDD
drive controllers
motor power
cable
motor feedback
AC motor
PZ5006F1.FH7
Fig. 1-2: Individual components of the digital drive
1.3 Supply units

HDD and HDS drive controllers are intended for connection to a HVE or
HVR supply module. These modules supply all the signal and power
voltages which the controller requires.
See also documentation "DOK-POWER*-HVE+HVR****-ANW*-EN-P"
HDD and HDS Drive Controllers 1st Generation Drive controllers HDD / HDS 2-1
2 Drive controllers HDD / HDS
2.1 Configured drive controller

The structure of the drive controllers is modular. The basic unit is adapted
to a respective function by outfitting it with different plugin modules.
INDRAMAT supplies the drive controllers configured. The configuration is
determined by the required functions.
A configured drive controller is made up of the following components:
• drive controller - basic unit
• command communications module
• software module
• additional plug-in modules (HDS only)
• configuration type plate
Drive controller - basic unit
2 3 Configuration
4
1
type plate
5
0
6
9
8 7
(inserted)
2 3
4
1
5
0
6
9
8 7
and U1 SYS
mm ic TEM
CON
Co mun HDS
02.1
FIGU
RAT
comns
-W ION
100-
HDS HS01
02.1 -FW
atiodule
U -W10
0-D
1 DS
S 02
mo U2
U
.1
2 CO
VER
U3
U
3 COV
ER
U
4 COV
ER
U4
U
5 HSM
1.1-S
SE-02
TYS-
HDS0
2.1-W
100-
HS0
1-00
U1 U2 U3 U4
X2
i-
Addnal
X3
tio g-in
plu ule
d
mo
X4
S1
U5 H1
ft-
So re
wa dule
X6
moM
HS
U V W
PZ5009F1.FH7
Fig. 2-1: Components of a configured drive controller
2-2 Drive controllers HDD / HDS HDD and HDS Drive Controllers 1st Generation
Drive controller HDD

The HDD drive controller is equipped to control two motors.
It is outfitted with two slots into which a command communications
module for each axis can be inserted.
Due to the compact construction, the unit has no slots for additional plugin
modules. This means that only motors capable of operating with a HSF or
RSF motor feedback from INDRAMAT can be used. As a result, the drive
controller is only suited for machine axes not requiring direct linear scales.
2.2 Drive controller, basic unit

The slots in the basic unit are empty.
2.3 Command communication module

The term "Command communication module" defines various plugin
modules.
These plugin modules are the interface to the control.
The following command communication modules are available:
• SERCOS interface type DSS02.1M
• ANALOG interface type DAE02.1M
2.4 Software module

Type: HSM
The software module contains the firmware of the drive (operating
software) and stores all drive parameters. The firmware depends on the
selected configuration and the desired functions.
In the event that the unit must be replaced, the drive parameters can
simply be transferred to the replacement unit by inserting the software
module. The drive is then immediately available again with its specified
features.
2.5 Additional plugin module

The following plugin modules are defined by the term "Additional plugin
module":
Digital I/O cards Type: DEA04.1M, DEA05.1M, DEA06.1M

Digital interface cards for a bidirectional exchange of data, e.g., with a
PLC. Each interface has 15 inputs and 16 outputs. The individual types
are differentiated in terms of the internally set address.
Type: DEA08.1M, DEA09.1M, DEA10.1M

Type: DEA28.1M, DEA29.1M, DEA30.1M
Every interface has 32 inputs and 24 outputs as well as a CLC Bb-output.
Interface card for different Type: DEF01.1M, DEF02.1M

measuring systems for connecting incremental measuring systems with square-wave signal
output
Type: DLF01.1M
for connecting incremental measuring systems with sinusoidal signal
output
Type: DFF01.1M
for connecting singleturn GDS 1.1 measuring systems
Type: DAG01.2M
for connecting multiturn absolute encoders with SSI signal output
Type: DZF02.1M, DZF03.1

for connecting INDRAMAT gear-type encors
Type: DRF01.1M
for connecting measuring systems with analog output signals (e.g.,
resolver; maximum input voltage: +/-10V)
Note: Only one plugin module, i.e., a DLF, DZF or DRF may be used
at one time. It is not possible to combine these cards!
Interface card Type:DAK01.1M

The "ARCNET coupler card" is a plug-in card for use with the CLC-D
control card and represents the interface to an ARCNET bus system.
Type: DAK02.1M
The DAQ02 plug-in module is a plug-in card for use with the CLC-D
contro card. With it, it is possible to link several CLCs in an application
implementing several master axes.
This link can be a simple system, i.e., a primary ring only, or a redundant
system, i.e., both a primary and secondary ring.
Type: DSA01.1M
The plug-in module "Absolute encoder emulator" generates absolute
actual position values that correspond to SSI standards (Synchronous
serial interface).
Integrable control Type: CLC-D02.3M

Supports a centralized control of digital drive controllers in SYNAX
applications. (For details see document "SYNAX - Synchronization of
Machine Axes".)
Note: All plugin modules are described in detail in the document

"Plugin modules for digital intelligent drive controllers"; doc.
type DOK-DIAX04-PLUG*IN*MOD-PRJ2-EN-P.
2.6 Configuration type plate

The configuration type plate records the type designations of
• the configured drive controller
• the basic unit
• the software module
• and the plugin modules in slots U1 to U4
These type designations help identify which components are in which
slots.
In the event of a problem, these type designations on the configuration
type plate can be used to quickly identify the replacement parts needed.
Note: The configuration type plate identifies the modules the drive
controller is equipped with. Prior to startup, check to make
sure that the drive controller is equipped with what is listed on
the plate.
Any changes in the configuration should also be noted on the

configuration type plate!
SYSTEMCONFIGURATION
configured drive
controller drive HDS02.1-W100-HS01-FW
basic unit
type HDS02.1-W100-D
U
1 DSS 2.1M
U
2 COVER
slot U plugin module
designations 3 COVER type
U COVER
4
U software module
5 HSM01.1-SSE-02 type
configuration
rating TYS-HDS02.1-W100-HS01-00
plate type
COVER = no plugin module in slot TS0008F1.FH7
Fig. 2-2: An example of a configuration type plate
2.7 Type codes of the configured drive controller
basic unit configuration no.
Example H D D 0 2 . 1 - W 0 4 0 N - H Z 0 1 - 0 1 - F W
1. Product group
1.1 HDD . . . . . . . = HDD
2. Line
2.1 2 . . . . . . . . . . . . . . . . . . = 02
3. Version
3.1 1 . . . . . . . . . . . . . . . . . . . . . . . . . = 1
4. Cooling
4.1 air, internal (with built-in blower) = W
5. rated current
5.1 40 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . = 040
6. Other versions
6.1 none . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = N
7. Controller family
7.1 DIAX04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = H
8. Command communications
8.1 ANALOG interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . = A
8.2 SERCOS interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . = D
9. Function code id
Determined and documented by Indramat.
9.1 e.g.: 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = 01
10. Version of function id

10.1 e.g.: 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = 01
11. Firmware
TL0209F1.FH7
Fig. 2-3: Type codes HDD
Basic unit Configuration no.
Example H D S 0 2 . 1 - W 0 4 0 N - H S 0 1 - 0 1 - F W
1. Product group
1.1 HDS . . . . . . . .= HDS
2. Line
2 . . . . . . . . . . . . . . . . . . = 02
3 . . . . . . . . . . . . . . . . . . = 03
4 . . . . . . . . . . . . . . . . . . = 04
3. Version
1.........................=1
4. Cooling
4.1 air, internal (with built-in blower) = W
5. Rated current
40 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . = 040
75 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . = 075
100 A . . . . . . . . . . . . . . . . . . . . . . . . . . . = 100
200 A. . . . . . . . . . . . . . . . . . . . . . . . . . . = 200
6. Other versions
6.1 none . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = N
7. Controller family
7.1 DIAX04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = H
8. Command communication
8.1 ANALOG interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . = A
8.2 SERCOS interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . = S, T
9. Function id code
9.1 e.g.: 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = 01
10. Version of function id

10.1 e.g.: 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = 01
11. Firmware
11.1 Identification that firmware must be ordered as separate subitem
........................................... = FW
TL0210F1.FH7
Fig. 2-4: Type codes HDS
2.8 Technical data - an overview
Designation Symbol Unit HDD02.1- HDS02.1- HDS03.1- HDS03.1- HDS04.1-

W040N W040N W075N W100N W200N
Rated current Itype A 40 40 75 100 200
Peak current Ipeak A 40 per axis 40 75 100 200
Continuous current Icont A 15 / 10 20 / 15 40 / 30 50 / 35 85 / 50

(4kHz/8kHz)*) per axis
Power loss with Icont Pv W 95 per axis 125 220 280 530
Weight m kg 8 7.5 11 11 14,5
Power consumption for P24V W 40 20 20 20 20

signal processing from
24V-source **)
*) Clock frequency of the power section

**) Basic unit only; plugin module (configuration) see Fig. 2-6
Ambient application conditions
Permissible ambient temperature °C +5 ... +45

range with rated data
Maximum permissible ambient °C 55
temperature with derated data
Storage and transport temperature °C -30 ... +85
Installation elevation without meters max. 1000

reduction of rated data above
sea
level
Insulation classification C as per DIN VDE 0110
Protection category IP 10 per DIN 40 050
Fig. 2-5: Technical data of HDD and HDS
Power consumption of the Plug-in module type Power consumption ( in W)

plugin modules
CLC-D02.3M-FW 6,0
DAE02.1M 1,2
DAG01.2M 3,3
DAK01.1M 2,1
DAQ02.1M 3,0
DBS03.1M-FW 3,0
DEA04.2M 1,6
DEA05.2M 1,6
DEA06.2M 1,6
DEA08.1M 1,6
DEA09.1M 1,6
DEA10.1M 1,6
DEA28.1M 1,6
DEA29.1M 1,6
DEA30.1M 1,6
DEF01.1M 4,5
DEF02.1M 4,5
DFF01.1M 3,6
DLF01.1M 5,4
DRF01.1M 3,4
DSA01.1M 8,0
DSS02.1M 1,5
DPF05.1M-FW 1.2
DZF02.1M 5,9
DZF03.1M 5,9
Fig. 2-6: Power consumption of the plug-in modules
HDD and HDS Drive Controllers 1st Generation Planning the control cabinet 3-1
3 Planning the control cabinet
3.1 Ambient conditions and Installation elevation

Rated data The rated data of the controllers apply to
• ambient temperature of +5º to +45º C
• Installation elevations of 0 tois 1000 meters above sea level.
Exceeding rated data If the controllers are to be used outside of the indicated range, then it is
necessary to take the "Load factors" into consideration. This reduces the
output data.
⇒ In such cases as these, check whether the output data suffice for your
application. To determine the load factors, please see Fig. 3-1. Values
for temperature and installation exceeding those indicated are not
permissible!
Damage to units and loss of guarantee!

⇒ Controllers operated outside of specified ambient
conditions could be damaged. The guarantee is also
forfeited in such cases.
WARNING ⇒ Please, therefore, note the following intructions!
Load capacity
Load capacity dependent on dependent on
1
ambient temperature installation elevation of
1000 meters
1 0.8
Load factor fH
Load factor fT
0.8 0.6
0.6
40 45 50 55 0 1000 2000 3000 4000 5000
Ambient temperature in °C Installation elevation in meters above sea
DG0005F1.FH7
Fig. 3-1: Load factors as dependent on ambient temperature and installation

elevation
If either the ambient temperature or the installation elevation exceed

rated data:
⇒ Multiply the rated data listed in the technical data with the determined
load factor.
⇒ Ascertain that the derated data does not exceed your application.
If both the ambient temperature and the installation elevation exceed
rated data:
⇒ Multiply the determined load factors fT and fH.
⇒ Multiply the resulting vaue with the rated data of the controller listed in
the technical data.
⇒ Ascertain that the derated data is not exceeded by your application.
3-2 Planning the control cabinet HDD and HDS Drive Controllers 1st Generation
Protection category The controller satisfies protection category IP10 as per EN 60 529, edition
dated 10.91 (DIN VDE 0470-1).
It has been designed for mounting into a control cabinet or closed housing
(as per DIN VDE 0160, ed. 05.88, section 5.5.1.3 and 6.5.1.3).
Note: The control cabinet construction must also take the applicable
safety guidelines on protection against contract into account
(for industrial equipment, see, e.g., EN 60204/DIN VDE 0113,
Section 1)
3.2 The use of coolers in the control cabinet

The controller may only be operated without a reduction of rated data up
to an ambient temperature of 45° C. Resultingly, it may be necessary to
use a cooler.
Damage to controller is possible!

The operating safety of the machine is at risk.
⇒ Note the following instructions!
CAUTION
Avoid dripping or spraying The use of coolers results in condense water. The following instructions
water must therefore be complied with:
• Coolers must always be arranged so that condense water cannot drip
onto the electronic equipment within the control cabinet.
• Coolers must be placed so that the condense water collecting on the
blower of the cooler is not sprayed onto electronic equipment.
correct incorrect
cooler cooler
hot cold hot cold
air duct
electronic electronic
equipment equipment
control cabinet control cabinet
Eb0001f1.fh7
Fig. 3-2: Arranging the cooler on the control cabinet
correct incorrect
control cabinet control cabinet

air inlet air inlet
air air outlet

duct
cooler cooler
electronic electronic
equipment equipment
Eb0002f1.fh7
Fig. 3-3: Arranging the cooler on the front of the control cabinet
Avoiding condensation • Coolers must be set at 40° C and no lower!

• Coolers with self-adjusting temperature must be set so that the inside
temperature of the control cabinet is not lower than that of outside.
Temperature limit must be set at 40° C!
• Use only well-sealed control cabinet to avoid formation of
condensation by humid air entering the cabinet.
• If control cabinet must be operated with doors opening (startups,
servicing, etc.), then it must be ensured that, after the doors are
closed, the controller is at no time cooler than the air in the cabinet.
This could cause condensation. It is, therefore, necessary to run the
cooler even when the machine is off until the temperature of the air
inside the control cabinet and that of the installed units is the same.
3.3 Dimensional sheets

Mounting rails with type designation SUP-M01-HD (Part number: 271274)
should be used to fasten the drive controller into the control cabinet. It is
only available in a length of 750 mm and must be shortened as needed at
delivery.
The mounting rails are screwed onto the mounting panel. Screwing it into
every other slot is sufficient to fasten it into place.
Unit can be damaged as a result of incorrect

mounting orientation!
Danger of overheating.
⇒ Operate units in the mounting orientations indicated
CAUTION only.
14 x 50 =700 mm
750+/-1 mm
25+/-0.2 mm 50+/-0.2mm 12+/-0.1 mm

5.5+/-0.1 mm
26+/-0.2 mm
11+0.15 mm
5.5 mm
12 mm
X 3+/-0.15 mm
MB5017F1.FH7
Fig. 3-4: Mounting rails
contact guard
view without
L+
L-
X1
50
max. tightening torque

3 Nm
mounting rails
min.100
min.80
188
can be removed
min. mounting space

265
308
contact guard
56
min. 90
498
MB5021F1.FH7
Fig. 3-5: Dimensional sheet - HDD02.1
contact guard
view without
L+
L-
X1
50

3 Nm
mounting rails
min.100
min.80
188
can be removed
min. mounting space

265
308
contact guard
56
min. 90
498
MB5018F1.FH7
Fig. 3-6: Dimensional sheet - HDS02.1

contact guard
view without
2 Nm
A3
100
L+
L-
A1 A2
X1
3 Nm
mounting rails
min.100
min.80
188
can be removed
min. mounting space

265
308
contact guard
56
min. 90
498
MB5019F1.FH7

contact guard
view without
4 Nm
A3
150
A1 A2
L+
L-
X1
mounting rails
3 Nm
min.100
min.80
188
can be removed
min. mounting space

265
308
contact guard
56
min. 90
498
MB5024F1.FH7
3.4 Connection lines

Supply line routing • A distance of at least 100 mm between power and control or signal
cables (e.g., feedback cables) or
• use a metal cable duct to isolate
Metal cable duct
2...4 mm
Plastic cable duct
>100 mm
MB5008F1.FH7
Fig. 3-9: Cable duct variants
• Do not route control or signal cables near high frequency units,

magnetic fields (transformers, chokes, etc.) or high-voltage supply
lines.
Line lengths • Maximum motor cable length: 75 m
• Maximum feedback connection length: 75 m
Errors when controlling motors and moving

components
Mechanical injuries!
⇒ Clamping points or couplings reduce the maximum
CAUTION line length. Note the following!
The line lengths specified apply to:

• direct connections between drive controller and motor
• ready-made cables from INDRAMAT and
• an ambient temperature of ≤ 40° C per EN 60 204
3.5 Measures against interference sources in the control

cabinet
To maintain the limits of class B (rf interference level N) per DIN VDE
0470-1, ed. 11.92 and table 1 per DIN EN 55014, ed. 12.93 at the
machine (in particular when operating within a residential and light
industrial area), it applies:
• route motor power cable shielded or use a shielded motor power cable
• use shield attachment an controller
• use a suitable interference suppressioin filter in the mains supply line
of the machine or plant and make sure it is properly mounted and
operated
If inductive loads (e.g., chokes, contactors or relays) per contact or semi-
conductor are switched, then these loads must be interference
suppressed:
• use freewheeling diodes with three-phase current actuation
• use a contactor type-related RC-interference suppression module with
alternating current actuation
• interference suppression elements must be mounted at the inductance
(e.g., contactor coil). The suppression effect could otherwise be
considerably reduced.
• do not use varistors
If high-frequency equipment is to be used (e.g., components of
eloxidating devices):
• locate and wire such equipment outside of the control cabinet
(depending on local conditions, a separate control cabinet may be
necessary).
Note: For details see the Project Planning Manual "Electromagnetic

Compatibility (EMC) in AC drives", doc. type DOK-GENERL-
EMV********-PRJ*-EN-P
Only the machine manufacturer can check whether the limit values are
being maintained or not.
HDD and HDS Drive Controllers 1st Generation Planning the electrical connections 4-1
4 Planning the electrical connections
4.1 General information

The electrostatic loads of persons and/or tools could damage either drive
controllers or PCBs when discharging over such. Therefore, please note
the following:
Error in controlling motors and moving components!

Electrostatic loads endanger electronic equipment and
their operating safety!
⇒ Bodies coming into contact with components and
CAUTION PCBs must be discharged by grounding!
These bodies can be:

• the soldering iron used for soldering
• the human body (ground by touching a condutive, grounded object)
• parts and tools (placed on a conductive surface)
Endangered parts may only be stored or transported in conductive
packaging.
Note: Indramat's terminal diagrams exclusively support the

development of the machine terminal diagrams. When wiring
the machine, use the terminal diagrams of the machine
manufacturer!
General notes • Route signal supply lines separate of load supply lines due to the
interference.
• Analog signals (e.g., command and actual values) must be fed via
supply lines.
• Mains, DC bus and power strands may not be connected with extra-
low voltages or be permitted to come into contact with such.
• During the conduction of a high voltage check or insulation check of
the electrical equipment of the machine, release or remove all
connections of the machine so avoid damaging the electronic
components within the machine (permissible as per VDE 0113).
INDRAMAT drive components are high-voltage and insulation checked
as per VDE 0160.
4-2 Planning the electrical connections HDD and HDS Drive Controllers 1st Generation
4.2 Connecting the basic unit

Overview
RS-232 interface or RS-485

connection for VT-100 terminal
or PC
8
U1 U2 U3 U4 U5 Software module
X2
- drive lock control 9 motor feedback
X3
- acknowledge drive lock connection

- ready to operate 7
- two analog diagnostics
outputs
fault reset key
X4
S1
H1 status display,
warning
and error
X6
4 motor temperature monitor

connection
motor brake connection
DC +24V external connection
connection with integrated for brake control
bus connection from
6
adjacent unit
6
connection to adjacent
unit with integrated bus
X1 connection
L+
L-
5 DC bus connection
ground connection 1
to supply module to adjacent unit
A1 A2 A3
3 ground connection
to motor
2 three-phase connection
of motor power cable
10 XS1 shield attachment for motor cable FA 5 0 4 9 F 1 . F H 7
Fig. 4-1: Front view of the basic unit with connections labelled
For explanation on points c .... l see the following pages.
power voltage
X1
drive controller
the following
(bus rails)
Bus connection
DC bus
L+
L-
Connection for optional interface modules as per
Command
Softwaremodul
U5
U1
communications
module HSM
relevant terminal diagrams
Additional
U2
plugin module
Additional
X4
U3
plugin module
vio 7
SDO 8
bl 4
SDI 15
Additional plugin rt 2
SCL 7
HDS drive controller
U4
module
Feedback-connection
FS 14 sw 3
(not with HDS02)
AC - Motor
UG 12 bn 12 12
C+ 10 gr 8
C- 3 rs 1
X3
S+ 9 bn 5
1
diagnostics
AK1 S- 2 gn 6
outputs
analog
2
0VM 0VM 4 ws 12 10
3 1 9
AK2
4
0VM
5
6
Bb
7
X6
Bb
8
AS+
7
starting
lockout
9
AS-
10 6
ASQ 0VB depents on
11
motor type
PTC/ NTC
ASQ 3
UB
2 H
X2
TM-
1 E
1 TM+
0VM
2 5 G
TxD TxD_232 BR-
3
4 F
U
RxD RxD_232
BR+
interface
4
serial
RTS A_485
Optional
holding
brake
5
CTS B_485
7 D
10 C
A3
B
M
A1 A2
3
L+
L-
A
X1
.
.
.
.
X5
shield attachment
flat-ribbon cable
bus connection
for motor cable

controller or supply
Motorkabel
24VExt
power voltage
previous drive
0VExt
XS1
module
(bus rails)
DC bus
from
24V
AP5151F1.FH7
Fig. 4-2: Connections of a HDS drive controller labelled
drive controller
the following
X1
power voltage
Bus connection
(bus rails)
DC bus
X4.2
1 9
L+
7
L-
8 vio
SDO
15 bl 4
SDI
Feedback-connection
7 r 2
SCL t
Command communications Command 14 sw 3
U1.2
FS
AC - Motor 2
module - drive 2 as per communications 12 bn 12 12
module - drive 2 UG
terminal diagram 10 gr 8
C+
3 rs 1
C-
X3.2
9 bn 5
S+
2 gn 6
1 S-
diagnostic
AK1 4 ws 12 10
U5.2
Softwaremodul
outputs
analog
2 0VM
0VM
3 HSM
AK2
4
X6.2
0VM
5
7
6
Bb 6
depents on
PTC / NTC
motor type
7 UB
Bb
axis 2
8 3
AS+ 0VB
starting
lockout
9 2 H
AS- TM-
10 1
ASQ TM+ E
11
ASQ 5 G
BR-
4 F
U
X2.2
BR+
X5.2
Optional
HDD drive controller
holding
0VM D
brake
2
TxD TxD_232
interface
3 C
A3
serial
RxD RxD_232
4
M
RTS A_485 A2 B
5
3
CTS B_485 A
7 A1
10
XS1
X4.1
1 9
Command communications SDO 8 vio 7

Command
U1.1
module - drive 1 as per communications SDI 15 bl 4

terminal diagram
Feedback-connection
module - drive 1 SCL 7 r 2
t 3
FS 14 sw
X3.1
AC - Motor 1
UG 12 bn 12 12
1 10 gr 8
diagnostic
AK1 C+
outputs
analog
2 3 rs 1
C-
axis 1
0VM
3 9 bn 5
AK2 S+
4 2 gn 6
0VM S-
5 0VM 4 ws 12 10
6
Bb
7
Bb
X6.1
8
AS+
starting
lockout
9 7
AS-
10 6
ASQ UB
depents on
PTC / NTC
11
motor type
ASQ 3
0VB
2 H
U5.1
Softwaremodul
X2.1
TM-
HSM TM+
1 E
1 5 G
0VM BR-
2
TxD TxD_232 4 F
interface
3 BR+
serial
RxD RxD_232
4
X5.1
Optional
RTS A_485
holding
5
brake
CTS B_485
7 D
10
A
A1
M
B
A2
L+
L-
C
X1
A3
.
.
.
.
shield attachment
flat-ribbon cable
for motor cable

bus connection
controller or supply
Motorkabel
24VExt
previous drive
0VExt
XS1
power voltage
module
from
(bus rails)
DC bus
24V
AP5152F1.FH7
Fig. 4-3: Connections of a HDD drive controller labelled
cGround connections to the HDD and HDS drive controllers are equipped with two ground
supply module connections (earthing) to the supply module:
• back wall of the unit and the mounting rails as well as
• the front of the grounding clip (see illustration)
Grounding clip
X1
L+
L-
A1 A2 A3
AP5153F1.FH7
Fig. 4-4: Ground connections - controller
Also see section 8-1, "Mounting the drive controller" for supplementary
information.
d+e+fMotor power cable INDRAMAT motor power cables should be used to connect drive
connection controller and motor.
In an INDRAMAT motor power cble are:
• three supply lines for the motor power connection and
• a line for the grounded conductor connection
• a separately shielded pair of lines for the motor temperature monitor
• a separately shielded pair of lines for the motor holding brake
• and a complete shield mounted to shield attachment
The motor power cable is available as a ready-made cable from
INDRAMAT. The cable can also be made of four twisted individual supply
lines (3 phases, 1 grounded conductor) with a separately conducted,
shielded supply line for temperature monitoring and the brake connection.
For supplementary technical data on connections and diameters, see the
relevant motor description.
Line length Maximum cable lengths equals 75 meters if INDRAMAT cables are used
(see sec. 3.4).
f Connector X6, Holding

brake, for temperature monitor
HDS
TM+
BR+
TM-
0VB
BR-
UB
X6
7
A1 A2 A3
XS1
shield 0VExt 24V
attachment for
motor cable 24VExt
G
C
H
A
E
F
U AC-Motor
M
3
PTC /
holding NTC
brake (depents motor type)
AP5154F1.FH7
Fig. 4-5: Motor cable , holding brake and temperature monitor connection
If a motor holding brake is used, then it is necessary to

connect an external 24V three-phase voltage source.
The 0Vext ( = 0VB ) must be galvanically connected
with the reference potential or housing of the drive
ATTENTION
controllers!
Current consumption of the holding brake is listed in the Project Planning

Manual of AC motors.
The AC motor holding brake is not a working brake. It wears down after
about 20,000 motor revolutions against the closed brake disc.
Note: To release a holding brake in the MHD/MKD servo motors,

apply the DC +24V +/- 10 % directly to the motor. The voltage
to release the brake is applied to X6/3 (+24V) and X6/6 (0V). It
must be ensured that the brake will release even if longer
motor power cables are used (voltage drop with long motor
power cables can be compensated by increasing supply
voltage (up to DC +26.5V) and/or with a regulated voltage
supply at X6/3 and X6/6.
Control of the motor holding The drive controller controls the holding brake.
brake
g DC bus voltage connection Adjacent drive controllers are generally connected via the connection
wires (shipped with the drive).
If a connection with the connection wires should not be possible, then
establish the connection using twisted supply lines that are as short as
possible (maximum length equals one meter, minimum diameter 16mm²).
h Connector X1, bus The control electronics of the drive controller receive their power via
connection connector X1. The connection starts at the supply unit and runs to the
drive controller with the help of the flat-ribbon cable integrated into the
units. Maximum length here also equals one meter (if extensions are
used)!
i Connector X3, Analog X3

outputs, Ready to operate,
Starting lockout
U5 1
AK1
2 Analog
X2 OVM
3 diagnostic
AK2
4 outputs
0VM
5
X3
6 Bb contact
Bb
7
Bb
8
AS+
9
AS- Starting
10
ASQ lockout
11
ASQ
X3
X4
AP5155F1.FH7
Fig. 4-6: Connector assignment - X3
Analog diagnostic outputs, AK1 Analog diagnostic outputs are outputs over which drive-internal variables
AK2 can be generated for test purposes (e.g., with startups). For detailed
information on analog diagnostic outputs, see documentation "DIAX04
Function Description".
Current load capacity: 4 mA
Output voltage: DC +/-10 V
Ready to operate contact Bb Once the ready to operate contact "Bb" closes, then the drive controller is
ready to receive power.
Contact "Bb" closes once power voltage is on and all monitoring functions
have signalled they are operational.
Contact "Bb" can be used, e.g., to evaluate the controls so that it can
recognize, in the event a unit, in hardware terms, is defective, which drive
controller in the drive package has failed.
Circuit load: DC 24 V, 1 A (maximum = duration)
Minimum load of contact: 10 mA
Note: The direct connection of a mains contactor via contact Bb is

only permissible if the ON current does not exceed 1A. Higher
currents can cause the relay to fail. The use of varistors as
protective circuits is not recommended as these age. This can,
in turn, cause an early failure of the connected components
and thus the unit itself as well.
Starting lockout AS+, AS-, ASQ, The starting lockout is a safety mechanism to secure against
ASQ unintentional startups of the connected motor in the event an error occurs.
It serves to securely switch off separate working areas within a machine
or plant.
Note: A starting lockout does not bring moving drives to a standstill.
Supplementary information on starting lockouts is outlined in the

description "Starting lockout function in DDS drive controllers"
DOK-DIAX02-DDS*ANL*FKT-ANW1-EN-P.
AS+, AS-:
• control inputs for relay coils

• voltage: DC 20 .... 30 V
• power: 1.5 W
ASQ, ASQ:
Potential-free feedback contact which acknowledges the actuating of the

starting lockout to an external control.
Breaking capacity: DC 24 V, 1 A (maximum = duration)
The actuation of the relay of the starting lockout in the drive controller is
confirmed by the closing of the potential-free feedback contant (output
ASQ - ASQ) to the external control.
To activate the starting lockout, apply a voltage of DC *20 to 30 volts
between AS+, AS-.
j Connector X2, Serial
interface
This serial interface supports the parametrization of the controller with a
PC with the help of suitable software (e.g., SERC-TOP or DRIVE-TOP).
It can be operated as RS-232 or, from device index A07 onwards, as RS-
485.
The RS-232 interface
The RS-232 interface enables:

• a maximum number of participants of 1
• a transmission length of up to 15 meters
• transmission rates of 9600/19200 baud
When using DriveTop, only one drive can be parametrized via the RS-232
interface.
max. 15 m
cable: IKB0005 cable: IKB0003

X2
2 2
RxD TxD
3 3
TxD RxD
5 4
GND RS485+
4 5
DTR RS485-
6 7
DSR 0V
7
RTS 1)
8
PC CTS
1)
D-SUB 9pol. D-SUB 15pol D-SUB 15pol.

miniature
GND and 0V are connected via the inner screen of the cable.
1) Connector outer screen to ground potential (strain relief of metallic
connector case) on PC side and on device side.
AP5158F1.FH7
Fig. 4-7: Connecting a PC using the RS-232 interface
RS-485 Interface
The RS-485 interface enables:

• the implementation of a serial bus with up to 31 participants connected
via a two-wire line (half duplex mode).
• a transmission length of up to 500 meters
• transmission rates of 9600/19200 baud
• the implementation of central PC-supported visualization unit
The RS-485 can be used to start up several DKCs with DriveTop without
having to plug into a different socket of of the interface cable.
The following solutions for operations with RS-485 are:

• RS-232/RS-485 converter between PC and drives
• RS-485 plug-in cards in PC
Please contact your PC supplier to find the solution for your application.
Installation guidelines for interface lines
Note: Details are outlined in the Project Planning Manual

"Electromagnetic compatibility (EMC) of drives and control
systems",
Doc. type DOK-GENERL-EMV********-PRJ-EN-P*
Connector for RS-485 interface
axis 1 INS0644 axis 2 INS0644

X2 IKB003 X2 IKB003
X1 X1
4 4 1 4 4 1
RS485+ 2
RS485+ 2
5 5 5 5
RS485- 3
RS485- 3
7 7 7 7
SGND SGND
12 12 12 12
+5V +5V
1 1
3) 2
3) 2
3 3
10
2) 10
150
10 2) 10
150
GND X2 GND X2
1) 1)
to further
devices
INK0572 RS232/RS485 converter
or PC plugin card 0V AB
RS 485
X2 X2
PC
DANGE DANGE
High V oltage. High V oltage.
Danger of electrical shock. Danger of electrical shock.
Do not touch electrical connec tions Do not touch electrical connec tions
for for
5 minutes after switching power 5 minutes after switching power
Read and follow "Safety Read and follow "Safety
Instructions for Electrical Drives" Instructions for Electrical Drives"
manual, manual,
DOK-GENERL-DRIVE******-SVS... DOK-GENERL-DRIVE******-SVS...
1)Connect outer screen to ground potential on PC side or converter side (strain relief of metallic
connector case)
2)Connection of device ground with the connector case with the fixation screws of the connector
3) If the drive controller is fitted as the geometrically last participant of a RS- 485 bus, activate the bus
termination. Shift switch to I.
Ap5160f1.fh7
Fig. 4-8: Example on how to connect an RS-485
k Connector X4, Motor An HSF or RSF INDRAMAT motor feedback is connected at X4 in

feedback compliance with the terminal diagram of the motor implemented. If any
other type of motor encoder is connected, then it is necesesary to use an
appropriate additional plugin module.
The same guidelines as apply to the power cable (see section 4) also
apply to the connection between drive controller and motor feedback.
l&Connector XS1, Shield

bracket of motor cable The entire shield of the motor cable is mounted to shield bracket XS1
using the enclosed clamp fitting. It is matched to the diameter of the cable
by simply selecting the relevant clamp base on the mounting panel. The
cable output direction can be either horizontal or vertical and is achieved
by adjusting the mounting panel.
Notes
HDD and HDS Drive Controllers 1st Generation Accessories 5-1
5 Accessories
5.1 LWLs (Fiber optic cables)

Controllers with SERCOS interface are connected via LWLs to the
superordinate controls.
The LWLs (cable, connector and/or ready-made LWL) must be ordered
separately.
Supplementary information about "LWLs" is outlined in the document
"LWL Handling" (doc. no.: 209-0090-4101-xx).
This document discusses the following points:

• LWLs in general
• basic plans for optical transmission systems
• routing instructions for LWLs
• dampening measurements of ready-made LWLs
• available LWL-FSMA plugin connectors and LWLs
• instructions on making an FSMA connector
• tools for making LWLs
Use the illustration below to determine the order information for the LWLs
in the entire system.
Selecting LWL connections
CNC
IKO0985 / . . . (for routing outside of
SERCOS cabinet)
Interface
length in meters
ø 2mm 2 3 2 3 2 3 2 3
4
4
1
1
0
5
6
6
9
8 7 8 7 8 7 8 7
2 3 2 3 2 3 2 3
4
4
1
1
0
5
6
6
9
8 7 8 7 8 7 8 7
LWL ring
ø 6mm
IKO0982/ . . . depends on
arrangement
IKO0982 /
LWL plugin coupling unit
(control cabinet leadthrough) length in meters
part no. 252 524
AP5157F1.FH7
Fig. 5-1: Selecting ready-made LWLs
5-2 Accessories HDD and HDS Drive Controllers 1st Generation
Notes
HDD and HDS Drive Controllers 1st Generation Transport and Storage 6-1
6 Transport and Storage
6.1 General instructions

Transportation • Use suitable transportation equipment.
• Use shock-absorbant supports if excessive shocks and vibrations
could occur during transport.
• Electrostatcally endangered components (e.g., plugin modules) may
only be transported in conductive packaging.
Storage • Permissible temperature range for storage and transport: -30° C to

+85° C
• Store dry, dust and shock free.
• Electrostatcally endangered components (e.g., plugin modules) may
only be stored in conductive packaging.
6-2 Transport and Storage HDD and HDS Drive Controllers 1st Generation
Notes
HDD and HDS Drive Controllers 1st Generation Identifying the Merchandise 7-1
7 Identifying the Merchandise
7.1 Delivery slip and barcode sticker

The delivery slip lists the merchandise of the entire delivery by name and
order designation.
On the packaging of the controller itself there are barcode stickers which
identifies it.
Fig. 7-1: Barcode sticker on the packaging of a HDD / HDS (Example)
7-2 Identifying the Merchandise HDD and HDS Drive Controllers 1st Generation
7.2 Type plate of the drive controller

Position of the type plate The controller is clearly identified by two type plates (see Fig. 7-2) :
• type plate of the basic unit (on the top of the unit)
• type plate of the complete configuration (on the inserted card, next to
the plugin modules)
type plate -
basic unit
configuration
type plate
X1
L+
L-
PZ5007F1.FH7
A1 A2
A3
Fig. 7-2: Position of the type plates
7.3 Other type plates

Firmware type plate The firmware type plate offers information on the type of firmware used
(= drive operating software). Like the configuration type plate, it is on the
inserted card, next to the plugin modules.
Ready-made cables The order number and the length of the cable are on the cable label
(cable marker).
146546-38687613 internal code id

type designation of
IKG4070 15.00 m length in meters
ready-made cable
19.04.98 230
testing date internal code id

TS0006F1.FH7
Fig. 7-3: Example: ready-made cable label
Cable parts Order designations for cable parts are printed on the cables.
HDD and HDS Drive Controllers 1st Generation Mounting and installation 8-1
8 Mounting and installation
8.1 Mounting the drive controller

Note: Please note permissible mounting conditions (see pg. 3.1)
Arranging the controller Arrange the drives with higher power needs and high currents as close to
the supply unit as possible.
Controller
High output Low output
Supply module
FA5052F1.FH7
Fig. 8-1: Preferred arrangement of units in the control cabinet
Fastening the mounting rails Mounting rails support the entire drive package. To be able to take up the
corresponding forces it is necessary to fasten the rails in at least every
second slot using an M5 screw.
As the mounting rails also conduct the potential compensation of the
drives, there must be good contact of the mounting rails and the mounting
panel. Therefore, it may be necessary to remove any paints or finishes on
the mounting panel within the area of mounting!
8-2 Mounting and installation HDD and HDS Drive Controllers 1st Generation
Cooling air outlet

80 mm free
at least
A 150 100 50
50
fasten
every 100 mm
with screw M5
x 16
and disc and
ring
drive controller with

module width 150
module width 100
module width 50
468.5 +1
Surface under
mounting rails
must be free of any
paints or lacquers!
100 mm free
at least
Unit Dim. A
Cooling air inlet
HVE 02.1 100
HVE 03.1 150
HVR 02.1 175
HVR 03.1 200
mounting rails available

in lengths a . . . m;
order designations ... 12
25 ±0.2 50 ±0.2 8
5,5 ±0,1
26
11
5.5
12 3
MB5025F1.FH7
Fig. 8-2: Mounting and fastening the mounting rails
HDD and HDS Drive Controllers 1st Generation Mounting and installation 8-3
Mounting the drive controllers

1. Hand the drive controller onto the mounting rails.
2. Push drive controller to the adjacent unit.
3. Tighten clamping screw (see Fig. 8-3).
mounting rails
88
X1
L+
L-
A1
A2
A3
clamping screws PZ5008F1.FH7
Fig. 8-3: Mounting the drive controller
8.2 Installation
• Establish ground connection with a grounding clip on the lower edge of
the drive controller.
• DC bus connection for the power connections must be released on the
underside of the unit and power connection to adjacent unit or supply
unit must be established.
• Close bus connection to adjacent unit using the integratef flat-ribbon
cable.
• Connect motor power cable with protective conductor and shield.
• Connect motor temperature sensor and holding brake (optional).
• Connect motor feedback.
8-4 Mounting and installation HDD and HDS Drive Controllers 1st Generation
Notes
HDD and HDS Drive Controllers 1st Generation Service and Testing 9-1
9 Service and Testing
9.1 Error diagnoses

The controller generates drive error messages via
• the SERCOS interface and
• the status display H1 on the front of the unit
Diagnostic notes in the In all controllers of the DIAX04 line, the meaning of the error messages
documentation and notes on fault clearance are identical. In the event of questions, just
check the relevant function description.
Diagnostics via the Hotline If a problem cannot be dealt with by the user, then please feel free to
contact our INDRAMAT customer service office of your location.
See also Supplement: Customer Service Locations - Sales & Service
Facilities
INDRAMAT's customer service can be reached at the following telephone

numbers during the hours indicated:
Phone number INDRAMAT's customer service can be reached from Mondays to Fridays
from 7.00 a.m. to 5 p.m. at the following phone number:
09352 / 40 - 4894 and 09352 / 40 - 4922
Service-Hotline The Service-Hotline can be reached at 0172 / 66 00 406 or 0171 / 333

8826 during the following hours:
Monday to Friday: 5.00 to 11.00 pm CET

Saturday: 8.00 am to 8.00 pm CET
Sundays and holidays: 9.00 am to 7.00 pm CET
Fig. 9-1: INDRAMAT hotline hours
To ensure a quick elimination of problems and errors, we would request

you to make a note of the following prior to calling INDRAMAT customer
service office, viz.,
• type data of the relevant controller, motor and gears
• the status
• any problem or diagnostics displays
• the software status.
9.2 Repairs and replacements

Repairs If the drive needs to be repaired, then:
• repairs may only be conducted by INDRAMAT customer service or
appropriately trained personnel.
Unit or component replacement Unit and component replacement for all DIAX04 units is outlined in the
document "DIAX04 - Notes on fault clearance". After a unit is replaced, it
is necessary to conduct a restart.
9-2 Service and Testing HDD and HDS Drive Controllers 1st Generation
9.3 High voltage check and insulation check

INDRAMAT drive components are tested as per DIN VDE 0160 for high-
voltage and insulation.
HDD and HDS Drive Controllers 1st Generation Index 10-1
10 Index
A
Accessories 5-1
Additional plugin module 2-2
AK1 4-7
AK2 4-7
Ambient conditions 3-1
Ambient temperature 3-1
Analog diagnostic outputs 4-7
Analog outputs 4-7
Arrangement of cooler 3-2
Arranging the controller 8-1
ASQ 4-8
B
Barcode sticker 7-1
Basic unit 2-1, 2-2
Bb 4-7
Bus connection 4-7
C
Cable duct 3-9
Command communication module 2-2
Complete shield 4-5
Component replacement 9-1
Condensation 3-3
Configuration 2-1
Configuration type plate 2-4
Connection labelling 4-2, 4-3, 4-4
Connector for RS485 - interface 4-11
Connector X1 4-7
Connector X2 4-9
Connector X3 4-7
Connector X4 4-11
Control 2-3
Coolers 3-2
D
DC bus voltage 4-6
Delivery slip 7-1
Diagnostic notes 9-1
Diagnostics 9-1
DIAX04 1-1
Digital I/O cards 2-2
Dimensional sheet HDD02.1 3-5
Dimensional sheet HDS02.1 3-6
Dimensional sheets 3-4
Drive controller HDD 2-2
HDD and HDS Drive Controllers 1st Generation
E
Error diagnoses 9-1
External voltage tests 9-2
F
Firmware 2-2
Firmware type plate 7-2
G
Ground connections 4-5
Grounded conductor connection 4-5
Grounding clip 4-5
H
Holding brake 4-6
Holding brake control 4-6
Hotline 9-1
I
Individual components 1-2
Installation 8-1, 8-3
Installation elevation 3-1
Installation guidelines for RS485 - lines 4-10
Interface card 2-3
Interfacekarten 2-3
Interference sources 3-10
L
Line lengths 3-9, 4-5
LWLs (Fiber optic cables) 5-1
M
Measuring system 2-3
Motor cable 4-6
Motor feedback 4-11
Motor holding brake 4-5
Motor temperature monitor 4-5
Motorl power cable 4-5
Mounting 8-1
Mounting rails 3-4, 8-1
Mounting the drive controllers 8-3
O
Operating software 2-2
P
Packaging 7-1
Phone number 9-1
Plugin modules 2-1
HDD and HDS Drive Controllers 1st Generation Index 10-3
Position of the type plate 7-2

Protection category 3-2
R
Rated data 3-1
Ready to operate 4-7
Ready to operate contact 4-7
Ready-made cables7-2
Repairs 9-1
Replacements 9-1
RS 485 Interface 4-10
S
SERCOS interface 2-2
Serial bus4-10
Serial interface 4-9
Service 9-1
Software module 2-2
Starting lockout 4-7
Starting lockout AS 4-8
Sticker 7-1
Storage 6-1
Supply line routing 3-9
Supply lines 3-9
Supply module 1-2
T
Technical data 2-7
Temperature monitor 4-6
Testing 9-1
Transportation 6-1
Type codes HDS 2-6
Type plate 7-2
U
Unit type plates 7-2
Notes
HDD and HDS Drive Controllers 1st Generation Sales & Service Facilities
Kundenbetreuungsstellen - Sales & Service Facilities

Deutschland - Germany
Vertriebsgebiet Mitte Vertriebsgebiet Ost Vertriebsgebiet West Vertriebsgebiet Nord
Germany Centre V/S Service Germany East V/S Service Germany West V/S Service Germany North V/S Service
INDRAMAT GmbH INDRAMAT GmbH INDRAMAT GmbH INDRAMAT GmbH

Bgm.-Dr.-Nebel-Str. 2 Beckerstraße 31 Harkortstraße 25 Kieler Straße 212
D - 97816 Lohr am Main D - 09120 Chemnitz D - 40849 Ratingen D - 22525 Hamburg
Telefon: +49 (0)9352/40-0 Telefon: +49 (0)371/35 55-0 Telefon: +49 (0)2102/43 18-0 Telefon: +49 (0)40/85 31 57-0
Telefax: +49 (0)9352/40-4885 Telefax: +49 (0)371/35 55-333 Telefax: +49 (0)2102/41 315 Telefax: +49 (0)40/85 31 57-15
Vertriebsgebiet Süd Gebiet Südwest INDRAMAT Service-Hotline

Germany South V/S Service Germany South-West V/S Service
INDRAMAT GmbH
INDRAMAT GmbH INDRAMAT GmbH Telefon: +49 (0)172/660 04 06
Ridlerstraße 75 Böblinger Straße 25
oder
D-80339 München D-71229 Leonberg
Telefon: +49 (0)171/333 88 26
Telefon: +49 (0)89/540138-30 Telefon: +49 (0)7152/9 72-6
Telefax: +49 (0)89/540138-10 Telefax: +49 (0)7152/9 72-727
Kundenbetreuungsstellen in Deutschland - Service agencies in Germany
Sales & Service Facilities HDD and HDS Drive Controllers 1st Generation
Europa - Europe
Austria V/S Service Austria V/S Service Belgium V/S Service Denmark V/S Service
Mannesmann Rexroth Ges.m.b.H. Mannesmann Rexroth G.m.b.H. Mannesmann Rexroth N.V.-S.A. BEC AS
Geschäftsbereich INDRAMAT Geschäftsbereich INDRAMAT Geschäftsbereich INDRAMAT Zinkvej 6
Hägelingasse 3 Industriepark 18 Industrielaan 8 DK-8900 Randers
A - 1140 Wien A - 4061 Pasching B-1740 Ternat
Telefon: +43 (0)1/9852540-400 Telefon: +43 (0)7221/605-0 Telefon: +32 (0)2/5823180 Telefon: +45 (0)87/11 90 60
Telefax: +43 (0)1/9852540-93 Telefax: +43 (0)7221/605-21 Telefax: +32 (0)2/5824310 Telefax: +45 (0)87/11 90 61
England V/S Service Finland V/S Service France V/S Service France V/S Service
Mannesmann Rexroth Ltd. Rexroth Mecman OY Mannesmann Rexroth S.A. Mannesmann Rexroth S.A.
INDRAMAT Division Ansatie 6 Division INDRAMAT Division INDRAMAT
4 Esland Place, Love Lane SF-017 40 Vantaa Parc des Barbanniers 270, Avenue de Lardenne
GB - Cirencester, Glos GL7 1YG 4, Place du Village F - 31100 Toulouse
Telefon: +358 (0)9/84 91 11
F-92632 Gennevilliers Cedex
Telefon: +44 (0)1285/658671 Telefax: +358 (0)9/84 91 13 60 Telefon: +33 (0)5 61 49 95 19
Telefax: +44 (0)1285/654991 Telefon: +33 (0)141 47 54 30 Telefax: +33 (0)5 61 31 00 41
Telefax: +33 (0)147 94 69 41
Hotline: +33 (0)6 08 33 43 28
France V/S Service Italy V/S Service Italy V/S Service Italy V/S Service
Mannesmann Rexroth S.A. Mannesmann Rexroth S.p.A. Mannesmann Rexroth S.p.A. Mannesmann Rexroth S.p.A.
Division INDRAMAT Divisione INDRAMAT Divisione INDRAMAT Divisione INDRAMAT
91, Bd. Irène Joliot-Curie Via G. Di Vittoria, 1 Via Borgomanero, 11 Via del Progresso, 16 (Zona Ind.)
F - 69634 Vénissieux Cedex I - 20063 Cernusco S/N.MI I - 10145 Torino I - 35020 Padova
Telefon: +33 (0)4 78 78 53 65 Telefon: +39 (0)2/92 36 52 70 Telefon: +39 (0)11/7 71 22 30 Telefon: +39 (0)49/8 70 13 70
Telefax: +33 (0)4 78 78 52 53 Telefax: +39 (0)2/92 36 55 12 Telefax: +39 (0)11/7 71 01 90 Telefax: +39 (0)49/8 70 13 77
Italy V/S Service Italy V/S Service Netherlands V/S Service Netherlands V/S Service
Mannesmann Rexroth S.p.A. Mannesmann Rexroth S.p.A. Hydraudyne Hydrauliek B.V. Hydrocare B.V.
Divisione INDRAMAT Divisione INDRAMAT Kruisbroeksestraat 1 Kruisbroeksestraat 1
Via de Nicola, 12 Viale Oriani, 38/A P.O. Box 32 P.O. Box 32
I - 80053 Castellamare di Stabbia NA I - 40137 Bologna NL - 5281 RV Boxtel NL - 5281 RV Boxtel
Telefon: +39 (0)81/8 72 30 37 Telefon: +39 (0)51/34 14 14 Telefon: +31 (0)411/65 19 51 Telefon: +31 (0)411/65 19 51
Telefax: +39 (0)81/8 72 30 18 Telefax: +39 (0)51/34 14 22 Telefax: +31 (0)411/65 14 83 Telefax: +31 (0)411/67 78 14
Spain V/S Service Spain V/S Service Sweden V/S Service Switzerland - East V/S Service
Mannesmann Rexroth S.A. Goimendi S.A. Rexroth Mecman Svenska AB Mannesmann Rexroth AG
Divisiòn INDRAMAT División Indramat INDRAMAT Division Geschäftsbereich INDRAMAT
Centro Industrial Santiga Jolastokieta (Herrera) Varuvägen 7 Gewerbestraße 3
Obradors s/n Apartado 11 37 S - 125 81 Stockholm CH-8500 Frauenfeld
E-08130 Santa Perpetua de Mogoda E - 20017 San Sebastian
Telefon: +46 (0)8/727 92 00 Telefon: +41 (0)52/720 21 00
Barcelona
Telefon: +34 9 43/40 01 63 Telefax: +46 (0)8/64 73 277 Telefax: +41 (0)52/720 21 11
Telefon: +34 937 47 94 00 Telefax: +34 9 43/39 17 99
Telefax: +34 937 47 94 01
Switzerland - West V/S Service Russia V/S Service Slowenia V/S Service Turkey V/S Service
Mannesmann Rexroth SA Tschudnenko E.B. DOMEL Mannesmann Rexroth Hidropar A..S.

Département INDRAMAT Arsenia 22 Elektromotorji in gospodinjski Fevzi Cakmak Cad No. 3
Chemin de l`Ecole 6 RUS - 153000 Ivanovo aparati d. d. TR - 34630 Sefaköy Istanbul
CH-1036 Sullens Rußland Otoki 21
Telefon: +90 212/541 60 70
SLO - 64 228 Zelezniki
Telefon: +41 (0)21/731 43 77 Telefon: +7 093/223 96 33 Telefax: +90 212/599 34 07
Telefax: +41 (0)21/731 46 78 oder/or +7 093/223 95 48 Telefon: +386 64/61 73 32
Telefax: +7 093/223 46 01 Telefax: +386 64/64 71 50
Europäische Kundenbetreuungsstellen (ohne Deutschland)

European Service agencies (without Germany)
HDD and HDS Drive Controllers 1st Generation Sales & Service Facilities
Außerhalb Europa - outside Europe

Argentina V/S Service Argentina V/S Service Australia V/S Service Brazil V/S Service
Mannesmann Rexroth S.A.I.C. NAKASE AIMS - Australian Industrial Mannesmann Rexroth

Division INDRAMAT Asesoramiento Tecnico Machinery Services Pty. Ltd. Automação Ltda.
Acassusso 48 41/7 Calle 49, No. 5764-66 Unit 3/45 Horne ST Divisão INDRAMAT
RA - 1605 Munro (Buenos Aires) RA - 1653 Villa Balester Campbellfield 3061 Rua Georg Rexroth, 609
Provincia de Buenos Aires AUS - Melbourne, VIC Vila Padre Anchieta
Telefon: +54 (0)1/756 01 40 BR - 09951-270 Diadema-SP
+54 (0)1/756 01 36 Telefon: +54 (0) 1/768 24 13 Telefon: +61 (0)3/93 59 02 28 [ Caixa Postal 377 ]
Telefax: +54 (0) 1/768 36 43 Telefax: +61 (0)3/93 59 02 86 [ BR-09901-970 Diadema-SP ]
Telefon: +55 (0)11/745 90 60
+55 (0)11/745 90 70
Telefax: +55 (0)11/745 90 50
Canada V/S Service China V/S Service China V/S Service China V/S Service
Basic Technologies Corporation Mannesmann Rexroth (China) Ldt. Mannesmann Rexroth (China) Ldt. Mannesmann Rexroth (China) Ldt.
Burlington Division Shanghai Office - Room 206 Shanghai Parts & Service Center 15/F China World Trade Center
3426 Mainway Drive Shanghai Internat. Trade Centre 199 Wu Cao Road, Hua Cao 1, Jianguomenwai Avenue
Burlington, Ontario 2200 Yanan Xi Lu Minhang District PRC - Beijing 100004
Canada L7M 1A8 PRC - Shanghai 200335 PRC - Shanghai 201 103
Telefon: +86 10/65 05 03 80
Telefon: +1 905/335 55 11 Telefon: +86 21/62 75 53 33 Telefon: +86 21/62 20 00 58 Telefax: +86 10/65 05 03 79
Telefax: +1 905/335-41 84 Telefax: +86 21/62 75 56 66 Telefax: +86 21/62 20 00 68
China V/S Service Hongkong V/S Service India V/S Service India V/S Service
Mannesmann Rexroth (China) Ldt. Rexroth (China) Ldt. Mannesmann Rexroth (India) Ltd. Mannesmann Rexroth (India) Ltd.
A-5F., 123 Lian Shan Street 19 Cheung Shun Street INDRAMAT Division INDRAMAT Division
Sha He Kou District 1st Floor, Cheung Sha Wan, Plot. 96, Phase III Plot. A-58, TTC Industrial Area
PRC - Dalian 116 023 Kowloon, Hongkong Peenya Industrial Area Thane Turbhe Midc Road
IND - Bangalore - 560058 Mahape Village
Telefon: +86 411/46 78 930 Telefon: +852 27/41 13 51/-54
IND - Navi Mumbai - 400 701
Telefax: +86 411/46 78 932 oder/or +852 27/41 14 30 Telefon: +91 (0)80/8 39 21 01
Telefax: +852 27/86 07 33 Telefax: +91 (0)80/8 39 43 45 Telefon: +91 (0)22/7 61 46 22
Telefax: +91 (0)22/7 68 15 31
Indonesia V/S Service Japan V/S Service Korea V/S Service Korea V/S Service
PT. Rexroth Wijayakusuma Rexroth Automation Co., Ltd. Mannesmann Rexroth-Seki Co Ltd. Seo Chang Corporation Ltd.
Jl. Raya Bekasi Km 21 INDRAMAT Division 1500-12 Da-Dae-Dong Room 903, Jeail Building
Pulogadung 1F, I.R. Building ROK - Saha-Ku, Pusan, 604-050 44-35 Yeouido-Dong
RI - Jakarta Timur 13920 Nakamachidai 4-26-44 Yeoungdeungpo-Ku
Telefon: +82 (0)51/2 60 06 18
Tsuzuki-ku, Yokohama-shi C.P.O.Box 97 56
Telefon: +62 21/4 61 04 87 Telefax: +82 (0)51/2 60 06 19
J - Kanagawa-ken 224-004 ROK - Seoul
+62 21/4 61 04 88
Telefax: +62 21/4 60 01 52 Telefon: +81 459/42-72 10 Telefon: +82 (0)2/7 80 82 08
Telefax: +81 459/42-03 41 +82 (0)2/7 80 82 09
Telefax: +82 (0)2/7 84 54 08
Mexico V/S Service South Africa V/S Service Taiwan V/S Service
Rexroth Mexico S.A. de C.V. HYTEC Automation (Pty) Ltd. Rexroth Uchida Co., Ltd.
Calle Neptuno 72 28 Banfield Road,Industria North No.1, Tsu Chiang Street
Unidad Ind. Vallejo RSA - Maraisburg 1700 Tu Cheng Ind. Estate
MEX - 07700 Mexico, D.F. Taipei Hsien, Taiwan, R.O.C.
Telefon: +27 (0)11/673 20 80
Telefon: +52 5 754 17 11 Telefax: +27 (0)11/673 72 69 Telefon: +886 2/2 68 13 47
+52 5 754 36 84 Telefax: +886 2/2 68 53 88
+52 5 754 12 60
Telefax: +52 5 754 50 73
+52 5 752 59 43
Kundenbetreuungsstellen außerhalb Europa - Service agencies outside Europe
Sales & Service Facilities HDD and HDS Drive Controllers 1st Generation
Außerhalb Europa / USA - outside Europe / USA

USA V/S Service USA V/S Service USA V/S Service USA V/S Service
Mannesmann Rexroth Corporation Mannesmann Rexroth Corporation Mannesmann Rexroth Corporation Mannesmann Rexroth Corporation
INDRAMAT Division INDRAMAT Division INDRAMAT Division INDRAMAT Division
5150 Prairie Stone Parkway Central Region Technical Center Southeastern Technical Center Northeastern Technical Center
USA -Hoffman Estates, IL 60192-3707 USA - Auburn Hills, MI 48326 3625 Swiftwater Park Drive 99 Rainbow Road
USA - Suwanee USA - East Granby,
Telefon: +1 847/6 45 36 00 Telefon: +1 248/3 93 33 30
Georgia 30174 Connecticut 06026
Telefax: +1 847/6 45 62 01 Telefax: +1 248/3 93 29 06
Telefon: +1 770/9 32 32 00 Telefon: +1 860/8 44 83 77
+1 770/9 32 19 03 +1 860/8 44 85 95
USA V/S Service
Mannesmann Rexroth Corporation

INDRAMAT Division
Charlotte Regional Sales Office
14001 South Lakes Drive
USA - Charlotte,
North Carolina 28273
Telefon: +1 704/5 83 97 62
+1 704/5 83 14 86
Kundenbetreuungsstellen außerhalb Europa / USA
Service agencies outside Europe / USA
Notes
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engineering

Titel DIAX04 HDD and HDS Drive Controllers 1st Generation

Type of documentation Project Planning

Document type code DOK-DIAX04-HDD+HDS****-PRJ2-EN-P

Internal file reference • 209-0074-4304-02

The purpose of this This documentation serves

Änderungsverlauf Document designation of previous Status Comments

Copyright  INDRAMAT GmbH, 1998

Published by INDRAMAT GmbH • Bgm.-Dr.-Nebel-Str. 2 • D-97816 Lohr a. Main

Dept. ECD (RS/JR)

Note This document is printed on chlorine-free bleached paper.

2 Drive controllers HDD / HDS 2-1

3 Planning the control cabinet 3-1

4 Planning the electrical connections 4-1

6 Transport and Storage 6-1

7 Identifying the Merchandise 7-1

8 Mounting and installation 8-1

8.1 Mounting the drive controller................................................................................................................ 8-1

9 Service and Testing 9-1

Customer Service Locations

1 Introducing the System

1.1 Drive Package - DIAX04

Fig. 1-1: Digital intelligent drive sytem - DIAX04

The modular concept of the DIAX04 INDRAMAT drive enables a flexible

1.2 The individual components of the digital DIAX04 drive

Fig. 1-2: Individual components of the digital drive

1.3 Supply units

2 Drive controllers HDD / HDS

2.1 Configured drive controller

Drive controller - basic unit

Drive controller HDD

2.2 Drive controller, basic unit

2.3 Command communication module

2.4 Software module

2.5 Additional plugin module

Digital I/O cards Type: DEA04.1M, DEA05.1M, DEA06.1M

Type: DEA08.1M, DEA09.1M, DEA10.1M

Interface card for different Type: DEF01.1M, DEF02.1M

Type: DZF02.1M, DZF03.1

Interface card Type:DAK01.1M

Integrable control Type: CLC-D02.3M

Note: All plugin modules are described in detail in the document

2.6 Configuration type plate

Any changes in the configuration should also be noted on the

COVER = no plugin module in slot TS0008F1.FH7

Fig. 2-2: An example of a configuration type plate

2.7 Type codes of the configured drive controller

basic unit configuration no.

10. Version of function id

Fig. 2-3: Type codes HDD

Basic unit Configuration no.

10. Version of function id

Fig. 2-4: Type codes HDS

2.8 Technical data - an overview

Designation Symbol Unit HDD02.1- HDS02.1- HDS03.1- HDS03.1- HDS04.1-

Rated current Itype A 40 40 75 100 200

Peak current Ipeak A 40 per axis 40 75 100 200

Continuous current Icont A 15 / 10 20 / 15 40 / 30 50 / 35 85 / 50

Weight m kg 8 7.5 11 11 14,5