2. Model Interpretation

DKR: Product series of high-power spindle drive power unit on the DIAX platform

04: Fourth-generation DIAX04 hardware topology architecture, different from the DKR03 with built-in braking structure

.1: Initial unified mechanical housing, the installation holes, dimensions of the derivative products in the same power range are common, mechanical interchangeability is compatible

W400: W = Built-in fan forced air cooling; 400 = Rated continuous output current 400A specification

N: Abbreviation for Non-Bleeder, without built-in integrated braking chopping circuit, the entire machine reserves an external braking dedicated terminal for external connection, it is necessary to connect an external braking resistor to consume the regenerated energy

BT29: Function configuration code 29, standard configuration includes SERCOS I optical bus + rotary transformer + incremental encoder dual-channel motor feedback, equipped with BT series expansion IO board, reserved external peripheral expansion slots

02: Second-generation hardware revision optimization version, optimized power circuit wiring, heat dissipation structure, compatible with the 01 version with the same configuration drive electrical interchangeability

FW: Firmware abbreviation, the DSM slot on the body is pre-installed with the original factory fixed motion control firmware, the factory-issued parameters are pre-written, the bare machine without the FW suffix model needs to purchase the firmware for burning and debugging separately

3. Technical Parameters

Rated three-phase main power input: 380～480VAC ±10%, industrial frequency 50/60Hz;

Auxiliary control power: AC230V ±10%, control circuit power consumption 300VA;

Continuous rated output current: 400A, instantaneous peak impact overload current 830A;

Applicable servo motor power: 55kW～132kW heavy-duty spindle / linear servo motor;

Standard communication: SERCOS optical digital bus;

Motor feedback: Rotary transformer + digital incremental encoder dual-channel compatible acquisition;

Brake configuration: N-type without built-in braking, full working conditions rely on external external braking resistor to discharge the bus regenerated energy;

Rated continuous working environment temperature: +5℃～+45℃, short-term limit of the enclosed cabinet + 55℃, the rated power of the 55℃ environment is reduced to 80% operation;

Protection grade: IP20 (only for installation inside the control cabinet, in accordance with IEC60529 standard);

Installation altitude: Altitude ≤ 1000m full power operation, above 1000m stepwise reduction for use, the maximum available altitude is 5000m;

Cooling method: Integrated large-power axial flow fan cooling on the body, the heat loss of the entire machine is 1800W;

Overall machine dimensions: L515mm×W258mm×H495mm, single machine net weight 24.2kg;

Electrical protection: Integrated overcurrent, overvoltage, undervoltage, bus short circuit, overheating, encoder break line full hardware lockout protection.

4. Interface and Communication Configuration

The three-phase incoming line of the main circuit, U/V/W motor power output use thickened copper bolt fastening terminals, the terminal base is engraved with phase sequence marking; the independent X11 dedicated terminal seat on the side of the body is the wiring position for external braking resistors; the integrated 24VDC control power terminals, multiple passive NO/NC fault interlock auxiliary contacts; two groups of SERCOS optical transceiver interfaces on the upper part of the machine body, equipped with original factory dust-proof protection cap; separate terminal interfaces are connected to the encoder cables, rotary transformer feedback cables; the DSM firmware slot on the front of the machine body is pre-installed with the FW fixed program module, a handheld debugging panel external connection slot is reserved; the entire machine has no native RS485 interface, Profibus-DP bus can be expanded through optional expansion card; the side of the body is reserved multiple original factory maintenance and testing terminals, convenient for on-site DC bus, power circuit insulation detection.

5. Core Functions Based on the pre-installed original factory firmware of FW, and by parsing the upper-level numerical control system SERCOS optical instructions, a wide-speed-range constant-power precise closed-loop control is achieved for high-power spindle motors; in the emergency stop, deceleration feedback power generation conditions, by relying on the external external braking circuit to consume the regenerated electrical energy, the stable DC bus voltage is maintained, and the overvoltage breakdown of the power IGBT module is avoided; the whole machine's full-loop real-time fault inspection is carried out, and when an abnormality occurs, the power output is immediately blocked, and the fault alarm passive signal is synchronously output through the side auxiliary contacts; the BT29 hardware architecture optimizes the frequent start-stop and high-low speed heavy-load switching conditions of heavy-load loads, suppressing the large current of the start-up impact; the modular split structure allows for independent disassembly and assembly of the power board, main control board, and firmware module, and the faulty components can be replaced individually, reducing maintenance costs; the FW firmware has a parameter power-off storage function, and the same model driver can be directly replaced for the entire machine without re-writing parameters for debugging.

6. Application scenarios

Main supporting: large numerical control gantry boring and milling machine spindles, heavy-duty bench drilling machine main drive, medium and large plastic extrusion and granulation main transmission, metallurgical roller conveyor auxiliary line transmission, large rotary printing machine drum drive, heavy-duty chemical fiber spinning complete set main transmission, imported high-precision heavy-duty grinding machine servo system; in the existing market, it is mostly used for the major overhaul of old European complete sets of automated equipment, the upgrading of production line automation, and the replacement of maintenance spare parts for the existing Indramat equipment after ABB's acquisition of Schaeffler.

7. Operating and maintenance instructions

1. Maintenance specifications: After the entire machine is powered off, wait for the DC bus capacitor to discharge for ≥ 20 minutes before opening the cover for maintenance operations to prevent residual high voltage on the bus from causing electric shock;

2. Quarterly maintenance: Clean the air intake of the blow-off fan, the internal air duct of the entire machine, remove dust from the main power circuit terminals, clean the SERCOS optical connector end faces of oil stains and dust, and check the tightness and insulation aging of the external braking resistor wiring;

3. Replacement determination: When the power module is broken down, the main control board hardware is burned out, the cooling fan is stuck and stops rotating, the driver has irregular frequent overcurrent / overvoltage protection trips, and the FW firmware module reports an error and cannot power on, the entire machine should be replaced;

4. Spare parts storage: Idle drivers are stored in a constant temperature and dry warehouse, with a relative humidity of ≤ 60%, away from corrosive industrial gases, intense mechanical vibration, and are prohibited from being inverted and stacked for storage.