RE82701 1099 Electronic Components

X
9
1
10 11 12 13 14 15 16
7
8
3
4
5
6
2
4
1
5
2
6
3
FU
N
SHIF ES
C
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CLR <<
S2
X30
S1
7
4
Ind
ram
at
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-CON
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Hig
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2
0
9
6
3
,
>>
STO
P
ENTE
R
STAR
T
X
T-IN
Y
OVE
R-
F1
AB
S
F2
F4
EIN
G
F7
JM
P
F1
RE
L
F5
AUS
G
F8
SU
B
F11
Z
OVE
R+
RE
F
F3
TIM
E
F6
COU
NT
F9
LA
B
F1
Hz
st op
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Controllers, Motors
Electrical Accessories
RE 82 701/10.99
>>
>>
8.8
S3
STAR Linear Motion Technology

Ball Rail Systems
Standard Ball Rail Systems

Ball Rail Systems with Aluminum Runner Blocks
Super Ball Rail Systems
Wide Ball Rail Systems
Miniature Ball Rail Systems
Cam Roller Guides
Accessories
Roller Rail Systems

Linear Bushings and Shafts
Linear Bushings
Linear Sets
Shafts
Shaft Support Rails
Shaft Support Blocks
Ball Transfer Units
Ball Screw Drives
Linear Motion Systems
Linear Motion Slides

Linear Modules
Compact Modules
Ball Rail Tables
Linear Actuators
ALU-STAR Profile System
Controllers, Motors, Electrical Accessories
Rexroth Star GmbH

D-97419 Schweinfurt
REG. No.
1617 - 03
are trademarks registered for

STAR, Ball Rail and
Deutsche Star GmbH, Germany.
Roller Rail is a trademark of

2
RE 82 701/02.99
Controllers
Motors, Electrical Accessories
From the Linear System Through to the Complete Solution
Servomotors
DKC Digital Controllers
Digital Controller DKC 11 / DKC 01

Digital Controller DKC 02
DKC Performance Data
DKC Ordering Code
Connections and Dimensions
10
13
14
17
18
24
DKS Digital Positioning Controller
26
- DLC Positioning Interface

- Performance Data
- DKS Ordering Code and Dimensions
32
36
38
DDS Digital Controller Modules
40
- CLM Analog Positioning Module

- Performance Data and Dimensions
- Ordering Data
46
48
50
Servomotor Dimensions
52
Three-Phase Motors
54
Frequency Inverter
54
- Technical Data and Dimension Drawings

- Ordering Code
58
62
Three-Phase Motor Data and Dimensions
63
Three-Phase Gear Motors with Integrated Frequency Inverter
64
Stepping Motors
66
Stepping Motor Power Output Section WD3-004 / WDM3-004
66
- Advantages/Functions
- Data and Dimensions
68
70
PC Controller Boards
72
- Dimensions
77
STAR step Positioning Controls
78
- Technical Data
Stepping Motor Equipment
Calculation Principles
80
84
88
RE 82 701/02.99
Drive Controls and Controllers

From the Linear System Through to the Complete Solution
Digital AC servomotor
MKD
MHD
LSF
LD
Linear Motion Systems

with Motor Drives
MKD
Linear
Motion Slides
MDD
Three-phase motor
Linear Modules
DFV
Ball Rail Tables
STAR
STAR
STAR
STAR
3-phase stepping motor
Compact
Modules
VRDM3
Motor calculations
RE 82 701/02.99
DKS
Digital positioning module

and DLC controls
The universal solution for
one axis
DDS
Digital controllers and

CLM analog positioning
module
The convenient solution for
multi-axis systems
Hz
sto
retur
star
ente
VF1000S
WD3
The
Complete Solution
STAR
STAR
STAR
STAR
Frequency inverter
The convenient solution
for driving three-phase
asynchronous motors
rn
sta
rt
ent
er
FU
N
SHIF ES
C
T
CLR <<
7
4
1
+/-
8
5
2
0
>>
9
6
3
,
X
T-IN
STO
F1
ENTE
R
STAR
T
AB
S
F4
EIN
F7
Y
OVER
-
>>
Power output section

for control cabinet
installation
sto
p
retu
>>
DKC
Digital controller
The low-cost solution for
single-axis and multi-axis
systems
JM
P
F10
F5
F8
Z
OVER
+
RE
F
F2
RE
L
AUS
F3
TIM
F6
SU
B
F11
COU
NT
F9
LAB
F12
engineering
mannesmann
Rexroth
STAR step
Hand
Auto
RS232
Deutsche Star
PC
PC controller board
Stepping motor controller
STAR
step
Single-axis and multi-axis

positioning controls with
power output section
The complete solution
STAR Motorauslegung
Berechnungsgrundlagen
Fr Systeme mit Zahnriementrieb:
Die Werte fr
- Beschleunigungszeit
- Beschleunigungsweg
- Beschleunigung
- Geschwindigkeit
knnen den jeweiligen Katalog des Fhrungssystems entnommen werden.
Fr Systeme mit
Kugelgewindetrieb:
Beschleunigungsverhalten bei
Servomotoren
Hinweis:
Die folgenden Berechnungsgrundlagen
dienen zur berschlgigen Auslegung der
Fhrungssysteme.
horizontale Einbaulage:
(1) MB = 0,8 Mmax MR
Mmax Mzul
vertikale Einbaulage:
(2) MB = 0,8 Mmax MR MG
Mmax Mzul
Gewichtsmoment
(vertikale Einbaulage)
Bedingung: S MG < MBremse
S : Sicherheit
empfohlener Wert S 2
1,561 10-3
(3) MG=
mlin P
i
siehe Tabelle im jeweiligen Fhrungssystem-Katalog
P = Spindelsteigung
i = Untersetzung
mlin = linear bewegte
Gesamtmasse
(mm)
(kg)
Grundplatte fest, Tischteil verfhrt:

mlin = mb + mfr
mb = bewegte Masse
(Tischteil)
mfr = Fremdmasse
Tischteil fest, Grundplatte verfhrt:
mges = Gesamtmasse
(mit Fhrungssystem)
mlin = mges mb
Massentrgheitsmoment von System

mit Fremdmasse
MB = maximales Beschleunigungsmoment des Motors

(Nm)
Mmax= maximales Drehmoment
des Motors
(Nm)
MR = Reibmoment
(Nm)
MG = Gewichtsmoment
(Nm)
Mzul = maximales
Antriebsmoment
(Nm)
fr Handling:
6 JM > Jfr
mlin = linear bewegte

Gesamtmasse
Jfr = Fremdmassentrgheitsmoment
JM = Massentrgheitsmoment Motor
fr Bearbeitung:
1,5 JM > Jfr
(kg)
(kg)
(kg)
Meff =
(MBreq + Mtot)2 tBreq 2 + Mtot2 tconst + Mtot2 tp

tcycle + tp
(kg)
(kgm2)
(kgm2)
(4) JS= aus Katalog des Fhrungssystems
82
RD 82 700/05.98
RE 82 701/02.99
DKC Digital Controller

Product Overview
The DKC intelligent digital controller is the low-cost solution with high
functionality for single-axis and multi-axis drive and control applications.
The DKC offers decisive competitive advantages in almost all areas of
automation in which linear or rotary movements need to be automated
and require a power rating of up to 10 kW.
Optimum cost/performance ratio
The DKC as a digital automation drive:
Flexible configuration with different interfaces:
4
1
5
2
DKC**.3
6
3
8.8
Programming module
with status and
diagnosis display
S2
In addition to many other fields of application, the DKC is

ideally suited for the following tasks:
Machining
Transporting
Positioning
Palettizing
AC
-CO
NT
RO
LLE
R
Hig
DA
NG
Da h vo
n lt
ER
Do ger age
!
o
5 mnot f ele
inu touch ctrica
tes
Re
aft electl sho
ad
er rica ck
Ele an
sw l co
ct
itch n
DO rica d follo
ing nne
l
be K-GE Drive w S
po ctio
fore NE s afe
we ns
r o fo
op RAL- man ty in
ff. r
era DR ua stru
tin IVE l
ctio
g
**
ns
**
for
**
*S
VS
Low power dissipation
Direct mains connection
RE 82 701/02.99
X30
S1
S3
Ind
ram
at
Universal use.
10 11 12 13 14 15 16
3
4
5
6
7
8
2
The matched combinations of the DKC compact controller and

MKD maintenance-free AC servomotors with resolver feedback
offer decided benefits.
9
1
DKC 11.* / DKC 01.*

analog interface
with stepping motor interface
with positioning interface for 64 storable positions
DKC 02.*
with SERCOS interface
DKC 03.*
with Profibus-DP interface for 64 storable positions
DKC 04.*
with Interbus interface for 64 storable positions
DKC 05.*
with CANopen interface for 64 storable positions
Built-in holding brake control
Software travel limitation
Incremental or absolute position actual value output
External reset possible
Maintenance-free synchronous motors
Enhanced operational reliability
Fast dynamic response
MKD
Automatic controller optimization
Simple start-up
RE 82 701/02.99
DKC Digital Controllers

Advantages
Controller
DKC
Voltage
(V) AC
DKC **.1-030-3
DKC **.3-040-7
DKC **.*-100-7
DKC **.*-040-7
DKC **.*-100-7
01.1-030-3
1-phase 230 10%
Single-phase direct mains connection

via mains filter to 230 V
Three-phase direct mains connection

via mains filter to 380 V - 480 V
**.1-040-7
**.3-***-*
3-phase 380 - 480 10%

1- or 3-phase
200 - 480 10%
For power ratings up to 1.1 kW, the

controllers can be directly connected
to single-phase mains supplies.
For power ratings up to 10 kW, the

controllers can be directly connected
to three-phase mains supplies.
Several controllers can be connected in

parallel to the respective mains through
a single power contactor.
* applies to all available models
L1
L2
L3
PE
L1
N
PE
Mains filter
Mains filter
Economical
Fast dynamic response
Safe
Digital control concept
Provided by favorable torque to moment

of inertia ratio.
Built-in holding brake control
Status and Diagnostics Display
The holding brake is directly controlled by

the controller.
Drive parametrization, control, monitoring,

and diagnostics are all carried out digitally.
Simple start-up
The start-up procedure is greatly simplified
by the user-friendly DRIVE-TOP start-up
and diagnostics program, which can be
run under Windows on a PC.
Lower overall costs
This is achieved by eliminating the need
for additional position sensors and providing for simple assembly and installation.
Incremental or absolute position
actual value output
Homing cycles no longer required due to
standard use of MKD motors with multiturn resolver feedback.
Direct output of all messages through

a two-digit, seven-segment display.
Maintenance-free synchronous
motors
Compact, maintenance-free MKD synchronous motors available in various versions,
equipped with a holding brake and multiturn resolver feedback.
Easily integrated
Multiple application functionality
The digital controllers can be supplied with
the following interfaces:
Software travel limit switches

These enhance the level of safety.
Enhanced operational reliability
Provided by maintenance-free synchronous
motors with temperature monitoring and
IP65 motor protection.
Programming module with status and
diagnosis display
For start-up, rapid diagnostics and re-start
without additional equipment after controller replacement.
Analog interface for speed and torque

loops.
Automatic parameter adjustment
Stepping motor interface for stepping
Parameters adjusted automatically due to
motor drive functions.
intelligent motor feedback to the controller.
Positioning interface for position control
Low power dissipation
with 64 storable positions.
SERCOS interface for full utilization of
Reduced power consumption due to IGBT
digital drive technology.
power output stages.
8
RE 82 701/02.99
Completely wired up in
the control cabinet with
the CLM controls
Available as a positioning unit completely
wired in the control cabinet, with circuit
diagram and documentation.
Triple-lock power switch
E-STOP mushroom-head pushbutton
Signal lamps for power on, setup/
automatic mode, malfunction.
Pushbutton for start/stop, axis forward/
backward, release brake
Selector switch for setup/automatic
mode
Key switch for parameter input
Inputs/outputs wired to terminal side
Keyboard for CLM positioning controls
installed in the control cabinet door
CL
M
7
4
1
+
5
2
X
X
4
1
10 11 12 13 14 15 16
3
4
5
6
7
8
2
5
2
6
3
9
1
4
1
10 11 12 13 14 15 16
7
8
2
3
4
5
6
5
2
6
3
X
X
4
1
5
2
6
3
8.8
X30
S1
S3
S2
8.8
X30
S1
S3
S2
8.8
Ind
ram
at
S2
ACCON
TRO
LLE
R
HOK
11
WAR
CLM
E:
01.
Further options on request:

External control desk
Additional instrumentation
Installation of additional control and
display elements
Installation of decade switches
Wiring on mounting board for installation in existing control cabinets
Programming to customer specifications
Additional operating/control terminal
Special configurations on request:

Control cabinet with DKC and PLC
Control cabinet with DKC and Siemens
Logo-Uhr (low-cost PLC)
Control cabinet with DKC and reversing
contactor circuitry
Control cabinet with DKC and controls
to customer requirements
Details of the CLM controls can be found
in the section entitled DDS Digital
Controller with CLM Analog Positioning
Module.
SOFT
LA
5
WAR
E:
01.
2-0
02.
10
11
12
13
14
15
High DAN
Dangevoltag GER
Do r
e
!
not of electri
5 minut
touch
cal
es
Read
afterelectri shock
cal
Electriand
switch
connn
DOK-Gcal follow
ing
ection
Drives
before ENERA
Safety powe
manu
r s
opera L-DRIV
instru off. for
al
ting E****
ctions
for
***
SVS
Ind
ram
at
ACCON
TRO
LLE
R
High DAN
Dangevoltag GER
Do r
e
!
not of electri
5 minut
touch
cal
es
Read
afterelectri shock
cal
Electriand
switch
connn
DOK-Gcal follow
ing
ection
Drives
before ENERA
Safety powe
manu
r s
opera L-DRIV
instru off. for
al
ting E****
ctions
for
***
SVS
Ind
ram
at
ACCON
TRO
LLE
R
High DAN
Dangevoltag GER
Do r
e
!
not of electri
5 minut
touch
cal
es
Read
afterelectri shock
cal
Electriand
switch
connn
DOK-Gcal follow
ing
ection
Drives
before ENERA
Safety powe
manu
r s
opera L-DRIV
instru off. for
al
ting E****
ctions
for
***
SVS
X30
S1
S3
SWIT
BEFOCH
MOD RE OFF
ULE CHANVOLT
Modu
GINGAGE
Span l nicht
nung unter
wech
seln
HARD
RE 82 701/02.99
9
1
CR
6
10 11 12 13 14 15 16
2
3
4
5
6
7
8
9
1
CL
Digital Controller DKC 11 / DKC 01

Interfaces
DKC 11 / DKC 01
Analog Interface
In this operating mode, the drive system
is adapted to conventional NC controllers
and works with 10 V analog speed command values.
Position actual values without

additional expense
Parametrically adjustable resolution

of position actual values
The controller transmits the current rotor

position to the NC controller as a position
actual value. No separate position encoders and encoder cables are needed for
indirect position control.
Depending on the application and its

accuracy requirements, 1 to 65536 increments can be parametrized as the
number of lines per revolution.
Drift-free holding of the drive
Incremental or absolute position

actual values
The position actual values can be output
either as incremental or absolute values.
Independently of the command value, the

servomotor can be stopped by means of a
switching input and held drift-free while
under active control.
Direct linear displacement measuring

system
A direct linear displacement measuring
system (e.g., magnetic or optical scale)
can be connected up to the DKC **.3
controller, thus making it possible to
drive a linear motor. (Input frequency
max. 200 kHz)
NC control
with position control loop, e.g., CLM
DKC 11.3 / DKC 01.3 digital controller

with analog interface
MKD / MHD
AC servomotor
Windows95 / NT
Parameters
Diagnosis
Operating data
Parameters
Diagnosis
Operating data
RS 232/RS 485
Drive system computer
Position
command
value
+W
Kv
Analog
speed
command
value
D
A
10 V
M
3~
A
Analog
interface
~~
-X
Position
interface
Position
High-resolution
position interface
actual
value
High-resolution
position interface
Linear scale
10
RE 82 701/02.99
DKC 01
Stepping Motor Interface
Enhanced operational safety
Electronic shaft at low cost

works as a position loop and simulates a
stepping motor. The position command
values are transmitted incrementally
through pulses from the NC control system
to the controller. The step width can be
parametrized from 16 to 65536 steps per
motor revolution.
The maximum stepping frequency of the

motor is independent of the load and is
limited only by the maximum speed. Unlike
a stepping motor, skipping of steps is
technically impossible.
Incremental encoder signals from a control

shaft are processed directly as position
command value pulses. Such an electrical
shaft can be implemented at low cost.
The incremental encoder output and the
stepping motor interface enable several
drives to be easily synchronized by
cascading.
Supports a wide range of input

signals
The stepping motor interface within the
controller can be parametrized to accept
the following signals from NC control
system:
- Quadrature signals
- Forward/backward signals
- Step and direction signals
Stepping motor
controls
DKC 01.3 digital controller

with stepping motor interface
MKD / MHD
AC servomotor
Windows95 / NT
Interpolation
Parameters
Diagnosis
Operating data
RS 232/RS 485
Step pulse
generation
Forwards
M
3~
Stepping motor
interface
Backwards
~~
Position
actual value
High-resolution
position interface
High-resolution
position interface
Linear scale
RE 82 701/02.99
11

Interfaces
DKC 01
Positioning Interface
works as a position loop and automatically
executes the selected positioning blocks.
Each of the 64 storable positioning blocks
contains the following information:
-
Travel mode (relative/absolute)

Target position
Travel speed
Acceleration
Torque damping
Full NC functionality with a PLC

control
Accurately defined motion sequences
Various control inputs and status outputs

guarantee full NC functionality.
Control inputs:
Approach to home position
Positive jogging
Negative jogging
Feedrate override
Reset
The positioning blocks can be parametrized

for target position, velocity, acceleration
and torque damping. Both relative and
absolute positions can be entered.
Programming the 'progression to next
block' function makes it possible to switch
to another positioning block with different
parameters without having to stop the
motor.
Example:
Motion profile with progression to next block
Status outputs:
In home position
Stopped
In target position
Fault warning
Simple, low-cost positioning axes
Selecting the positioning blocks through

control inputs eliminates the need for
positioning controller boards in the PLC.
PLC control

with positioning interface
MKD / MHD
AC servomotor
Windows95 / NT
Parameters
Diagnosis
Operating data
RS 232/RS 485
I / O board
Positioning
block selection
Stored
positioning blocks
Positioning
interface
M
3~
Control inputs
Status outputs
20 Position 1
21 Position 2
22
23
24
25 Position 64
~~
Position
actual value
High-resolution
position interface
High-resolution
position interface
12
RE 82 701/02.99

Interfaces
DKC 02
SERCOS Interface*
Highly flexible
Interference-free data exchange
This digital interface enables all the

facilities and benefits of digital AC
drive technology to be fully utilized.
The SERCOS Interface permits preselection

of and alternation between the following
4 operating modes during operation:
SERCOS exchanges data between the

CNC control system and the drive system
via fiber-optic cables, thus avoiding any
reciprocal interference between the
systems.
Position control with indirect position

detection in the motor, without or
without lag error.
*SERCOS Interface
Position control with direct position

detection via linear scale or rotary
encoder in the case of rotary indexing
tables, with or without lag error.
SERCOS Interface, the internationally

standardized drive interface (IEC 1491),
permits trouble-free interaction between
digital drives and NC control systems of
different manufacture while making the
best possible use of the respective product
characteristics.
Speed control
Torque control
CNC control system

with SERCOS Interface
MKD / MHD
AC servomotor
Windows95 / NT
Parameters
Diagnosis
Operating data
Parameters
Diagnosis
Operating data
RS 232/RS 485

SERCOS
interface
SERCOS
interface
M
3~
~~
High-resolution
position interface
High-resolution
position interface
Linear scale
RE 82 701/02.99
13

Interfaces
DKC 03
Profibus-DP Interface*
When equipped with a Profibus-DP
interface with extended FMS (Field bus
Message Specification) services, the drive
system will operate as a position loop,
automatically executing up to 64 stored
positioning blocks. Selected via the serial
Profibus-DP interface, the positioning
blocks contain the following:
-
Travel mode
Target position
Speed
Acceleration and deceleration
Torque damping
Full NC functionality with a PLC

control
Accurately defined motion sequences
Various control inputs and status outputs

guarantee full NC functionality.
Control inputs:
Approach to home position
Positive jogging
Negative jogging
Travel block selection
*Profibus-DP interface
Status outputs:
In home position
In motion
In target position
Travel block acknowledgment
Process data channel:
Transmission of realtime data
Parameter handling
Transmission of positioning block data
Cyclical speed and position target
commands
PLC control
The positioning blocks can be parametrized for travel mode, target position,
velocity, acceleration, deceleration, and
torque damping.
The positioning blocks can be executed
as absolute dimensional data for absolute
dimension programming or increments for
incremental data programming.
Profibus-DP interface is a serial PLC periphery bus system for rapid transmission of
I/O switching signals, such as enable, start,
stop, etc. Profibus-DP eliminates the need
for parallel I/O connections, thus considerably reducing the extent of wiring required.

with Profibus-DP interface
MKD / MHD
AC servomotor
Windows95 / NT
Parameters
Diagnosis
Operating data
RS-232/RS-485
M
3~
Stored
positioning blocks
Profibus
interface
Profibus
interface
20 Position 1
21 Position 2
22
23
24
25 Position 64
~~
Positioning
block selection
High-resolution
position interface
High-resolution
position interface
Linear scale
14
RE 82 701/02.99

DRIVE-TOP Diagnosis Program
Start-up and diagnosis
To ensure time-saving start-up and diagnostics, the drive system is (optionally)

delivered complete with a clearly-structured
applications manual and the user-friendly
DRIVE-TOP start-up and diagnosis program.
Applications Manual
(optional)
DRIVE-TOP
Start-up and
diagnosis program
CD-ROM
(optional)
The DRIVE-TOP diagnosis program runs

under Windows 95 and Windows NT.
DRIVE-TOP guides the user easily and unerringly through the individual start-up
steps.
PC1) with Windows TM 95

or Windows TM NT
Anwendungsbeschreibung
Resolver feedback cable

X
Connection for external encoder
9
1
Control cable for different interfaces2)

Supply cable for 24V DC control voltage2)
10 11 12 13 14 15 16
7
8
3
4
5
6
2
4
1
5
2
6
3
Programming module with diagnosis

display and firmware
Cable for RS 232/RS 485 interface2)

Respective unit interface
8.8
S2
X30
S1
S3
Ind
ram
at
cable2)
AC
-CON
TROL
LER
Hig
DA
NG
Da h vol
nge
ER
Do r tage
!
not of ele
5 min
tou ctri
ute ch cal
s aft ele sho
Rea
ctri ck
Ele d and er sw cal
ctri
itch con
DO cal foll
ing nne
ow
befK-GENDrives Saf
pow ctio
ore ERA
er ns for
ety
ope L-Dmanua ins
off
.
rat RIV l tru
ing E**
ctio
ns
***
for
**
SVS
1)
2)
DKC
Not supplied by STAR

Supplied by STAR only on request
RE 82 701/02.99
MKD
15

User-friendly Interface
Model code
Help functions
Graphic diagnostics display
The extensive help functions and the

graphic interface of the DRIVE-TOP
diagnosis program simplify drive system
start-up, parametrization and diagnostics.
The graphic block diagrams clearly indicate

the current internal status variables.
Graphic parametrization interface
Convenient start-up
Graphic function blocks clearly represent

the drive system programming structure.
Targeted questions guide the user quickly

and unerringly through the specific parameter setting sequence for the application.
Extensive help texts
Digital Controller
The program includes help texts for every

function.
DKC ** . * - *** - *
Interface
01 = Analog, positioning and
stepping motor interface
11 = Analog interface
02 = SERCOS interface
03 = Profibus-DP interface
04 = Interbus interface
05 = CANopen interface
Hardware version
01 = Controller generation 1
03 = Controller generation 3
Rated current
030 = 30 ampere
040 = 40 ampere
100 = 100 ampere
Link circuit voltage
3 = 300 V DC
7 = 700 V DC
16
RE 82 701/02.99
Performance Data
MKD Motor connected to the DKC Controller
Motor
MKD
Controller OF C nmax MdN

DKC
(%)
(min-1) (Nm)
025B-144 **.*-030 220 1 5600

025B-144 **.*-040 220 1 9000
0.81)
0.81)
041B-144 **.*-030 127 1 3000

041B-144 **.*-040 183 1 7000
041B-144 **.*-040 213 1 7000
071B-061 **.*-040 116 1 4400
071B-061 **.*-040 143 1 4400
071B-061 **.*-100 215 1 4400
Mmax - n100 - n90
M100 - M90 MKB - DC
JM
(Nm) (min-1) (min-1) (Nm) (Nm) (Nm) (%)

3.4 4750 4063
3.4 9000 9000
2.0
3.4
JB
mM
mB
MBr
(kgcm2)
(kg)
(kg)
(Nm) (kVA)
Umains
(V) AC
0.9
3.4
1.6
1.6
25
25
0.3
0.3
0.08
0.08
2
2
0.25
0.25
1
1
0.44
0.56
1 x 230
3 x 400
2.7
2.7
2.7
9.1 2333 1934 5.4 3.2

10.3 7000 7000 10.3 10.3
5.3 7000 7000 5.3 5.3
3.1
4.6
5.3
76
34
26
1.7
1.7
1.7
0.16
0.16
0.16
4.4
4.4
4.4
0.25
0.25
0.25
2.2
2.2
2.2
0.69
1.17
1.17
1 x 230
3 x 400
3 x 400
8.0
8.0
8.0
24.6 4400 3982 24.6

10.5 4400 4358 10.5
30.0 4353 3838 28.2
8.9
8.9
8.9
8.6
10.5
16.0
87
58
25
8.7
8.7
8.7
0.38
0.38
0.38
8.8
8.8
8.8
0.37
0.37
0.37
5
5
5
2.05
2.05
2.05
3 x 400
3 x 400
3 x 400
090B-047 **.*-040 106 1 2900 12.0

090B-047 **.*-040 121 1 2900 12.0
090B-047 **.*-100 215 1 2900 12.0
27.0 2839 2494 24.3

13.6 2900 2798 13.6
42.9 2477 2132 24.3
9.1
9.1
9.1
12.0 100
13.6 78
24.3 24
43.0
43.0
43.0
1.10
1.10
1.10
14
14
14
0.65
0.65
0.65
11
11
11
2.08
2.08
2.08
3 x 400
3 x 400
3 x 400
112B-024 **.*-040 68 1 2000 18.22) 28.9 2000 1889 28.9 12.6

112B-024 **.*-100 161 1 1900 28.0 100.2 1631 1399 61.0 27.2
112B-024 **.*-100 161 2 1800 42.0 100.3 1630 1399 75.6 41.8
18.2 100 192.0

42.4 44 192.0
42.5 98 192.0
9.50
9.50
9.50
34
34
34
1.9
1.9
1.9
20
20
20
2.02
3.04
4.66
3 x 400
3 x 400
3 x 400
112B-048 **.*-100 107 1 3300 28.0

112B-048 **.*-100 107 2 3300 28.52)
47.6 3300 3096 47.6 24.9

47.7 3300 3095 47.7 24.9
28.2 99 192.0
28.5 100 192.0
9.50
9.50
34
34
1.9
1.9
20
20
4.86
5.01
3 x 400
3 x 400
112C-024 **.*-100 136 1 1900 38.0

112C-024 **.*-100 136 2 1900 49.12)
81.6 1883 1651 78.1 34.9

81.3 1883 1651 78.1 34.9
48.3 62 270.0
49.1 100 270.0
9.50
9.50
41
41
1.9
1.9
36
36
4.00
5.44
3 x 400
3 x 400
112D-024 **.*-100 106 1 1900 48.0

112D-024 **.*-100 106 2 1900 48.22)
80.7 1900 1751 80.7 44.8

80.7 1900 1751 80.7 44.8
48.0 100 350.0

48.2 100 350.0
9.50
9.50
48
48
1.9
1.9
36
36
4.97
5.07
3 x 400
3 x 400
The maximum torque Mmax must be limited to the maximum permissible torque of the mechanical structure by adjusting the
parameter bipolar torque limit during initial start-up.
1) Motor with brake
2) Limited by controller's continuous rated current
* applies to all available models
Key to symbols used
RE 82 701/02.99
OF
Overload factor (parameter; input through controller software)
Cooling method: 1 = natural convection, 2 = fan-cooled
nmax
Maximum effective speed
MdN
Continuous standstill torque
Mmax
Maximum torque up to 400 ms duty cycle
-n100
- at 100% mains voltage up to break-point speed n100%
-n90
M100-M90
Torque at maximum speed for 100% or 90% mains voltage
MKB-DC
Short-time operating torque relative to duty cycle DC
JM
Moment of inertia of the servomotor
JB
Moment of inertia of the brake
mM
Motor mass
mB
Brake mass
MBr
Brake holding torque
Connected power
Umains
Mains connection
17

Ordering Code
Digital Controller DKC 01.*-040-7

analog, positioning and
40 ampere

analog interface
40 ampere

analog, positioning and
100 ampere
Digital controller DKC 11.*-100-7

analog interface
100 ampere
Part
number
Via mains
filter with
additional
bleeder
Via mains
filter
Direct mains
connection
No. of axes
Designation
Mains filter for

motor LD (single-phase)
Power supply
DKC11.* with analog interface,

DKC01.* with analog, positioning
and stepping motor interface
Power section
DKC
(= number of
controllers)
Motor
assignment
MKD 025B-144
MKD 041B-144
MKD 071B-061
1132-140-00 MKD 090B-047
MHD (DKC1.3 only)
LSF (DKC1.3 only)
LD (DKC1.3 only)
MKD 025B-144
MKD 041B-144
MKD 071B-061
1132-840-00 MKD 090B-047
MHD (DKC11.3 only)
LSF (DKC11.3 only)
LD (DKC11.3 only)
01
02
00
01
11
21
03
04
01
02
00
01
11
21
03
04
MKD 025B-144
MKD 041B-144
MKD 071B-061
1132-110-00 MKD 090B-047
MKD 112*-***
MHD (DKC1.3 only)
LSF (DKC1.3 only)
01
MKD 025B-144
MKD 041B-144
MKD 071B-061
1132-810-00 MKD 090B-047
MKD 112*-***
MHD (DKC11.3 only)
LSF (DKC11.3 only)
02
00
01
11
03
04
01
02
00
01
11
03
04
* applies to hardware version 3
Ordering example
Ordering data
Explanation
Part number 1132-840-00
DKC 11.*-040-7 Digital Controller
Power connections
= 01
Mains connection via mains filter
Power section
= 03
DKC digital controllers to operate three MKD motors
Multi-axis controls
= 31
CLM control system for 3 axes with 16 inputs and 16 outputs
Control cabinet
= 31
Completely wired control cabinet with operating controls and

displays in control cabinet door
DKC controller software = 01
Start-up and diagnostics software for DKC Controller
CLM control software
= 01
Motion Manager PC program for programming and

parametrizing the CLM control system
DKC documentation
= 13
Documentation on DKC Controller (German, in triplicate)
Multi-axis controls
documentation
= 13
Documentation on CLM multi-axis control system

(German, in triplicate)
18
RE 82 701/02.99
Multi-axis
CLM controls
Control
cabinet
(completely
wired)
Software
DKC controller
(DKC start-up
and optimization)
Documentation
DKC controller
Software
CLM control
Documentation
multi-axis controls
without
16 Is
16 Os
80 Is
48 Os
without
00
00
00
11
13
21
23
31
33
41
43
11
13
21
00
23
31
33
41
43
without
CD
with- Motion without Manager out
German English CD-ROM1) with- German English

D
E
D
E
out
D
E
11
00
01
00
01
11
(1 copy)
00
00
11
13
21
23
31
33
41
43
11
13
21
00
23
31
33
41
43
1)
21
02
00
(2 copies)
12
22
31
41
(2 copies)
13
(3 copies)
12
22
(2 copies)
13
23
(3 copies)
(1 copy)
03
-
21
(1 copy)
00
00
23
(3 copies)
11
21
(1 copy)
00
01
00
12
22
(2 copies)
13
23
(3 copies)
The CD-ROM contains the documentation for the controller and the multi-axis controls
Motor and feedback cable to DKC
Motor assignment
Part number,
Length in m
(max. 75 m)
MKD 025B-144
MKD 041B-144
MKD 071B-061
MKD 090B-047
MKD 112B, uncooled
MKD 112C, uncooled
MKD 112D, uncooled
RE 82 701/02.99
19
Preassembled cable options

Motor side
Controller side
with connector
for
DKC**.1
DKC**.3
1130-001-17,
01
10
11
1130-001-25,
07
12
1130-001-40,
08
13

Ordering Code
100 ampere
MKD 025B-144
MKD 041B-144
MKD 071B-061
1132-240-00 MKD 090B-047
MHD (DKC2.3 only)
LSF (DKC2.3 only)
LD (DKC2.3 only)
MKD 025B-144
MKD 041B-144
MKD 071B-061
1132-210-00 MKD 090B-047
MKD 112*-***
MHD (DKC2.3 only)
LSF (DKC2.3 only)
40 ampere

Profibus-DP interface
100 ampere
1132-340-00
1132-310-00
Via mains
filter with
additional
bleeder
01
02
00
01
11
21
03
04
01
02
01
00
11
03
04
Power supply
Direct mains
connection
No. of axes
Part
number
Via mains
filter
DKC03.* with Profibus-DP interface
Designation
Power section
DKC
(= number of
controllers)
Motor
assignment
Mains filter for


SERCOS interface
Via mains
filter with
additional
bleeder
40 ampere
Via mains
filter

SERCOS interface
Part
number
Direct mains
connection
No. of axes
Designation
Mains filter for

Power supply
DKC02.* with SERCOS interface
Power section
DKC
(= number of
controllers)
Motor
assignment
MKD 025B-144
MKD 041B-144
MKD 071B-061
MKD 090B-047
MHD (DKC3.3 only)
LSF (DKC3.3 only)
LD (DKC3.3 only)
MKD 025B-144
MKD 041B-144
MKD 071B-061
MKD 090B-047
MKD 112*-***
MHD (DKC3.3 only)
LSF (DKC3.3 only)
01
02
00
01
11
21
03
04
01
02
00
01
11
03
04
* applies to hardware version 3
20
RE 82 701/02.99
Software
DKC controller
(DKC start-up
and optimization)
Documentation
DKC controller
without
with
without German English CD-ROM

D
E
D
E
11
01
(1 copy)
00
02
(2 copies)
21
(1 copy)
00
12
22
(2 copies)
31
41
13
23
(3 copies)
03
(3 copies)
Software
DKC controller
(DKC start-up
and optimization)
Documentation
DKC controller
without
with
without German English CD-ROM

D
E
D
E
11
01
(1 copy)
00
02
(2 copies)
03
(3 copies)
RE 82 701/02.99
21
(1 copy)
00
12
22
(2 copies)
31
41
13
23
(3 copies)
21

Ordering Data For Single Components
DKC controllers
Designation
Firmware
DKC01.3-040-7
DKC11.3-040-7
DKC02.3-040-7
DKC03.3-040-7
DKC4.3-040-7
DKC5.3-040-7
DKC01.3-100-7
DKC11.3-100-7
DKC02.3-100-7
DKC03.3-100-7
DKC4.3-100-7
DKC5.3-100-7
Analog, positioning and stepping motor interface

Analog interface
SERCOS interface
Interbus interface
CANopen interface
Analog, positioning and stepping motor interface
Analog interface
SERCOS interface
Interbus interface
CANopen interface
Part number
1132-143-01
1132-843-01
1132-243-01
1132-343-02
1132-443-02
1132-543-02
1132-113-01
1132-813-01
1132-213-01
1132-313-02
1132-413-02
1132-513-02
Mains filter
P
Designation
Description
Mains filter
Mains filter
NFE02.1
NFD02.1
1 x 230 V, 10 A
3 x 380 - 430 V, 10 A
1 x 230 V, 8 A
3 x 380 - 480 V, 8 A
Part number
8617-001-06
8617-002-06
1130-895-22
1130-895-02
Additional components
Designation
Description
NTM1.1-024-02
BZM01.3-01-07
CZM01.3
Mains filter 24V 2 A

Additional bleeder
Additional capacitor module
Part number
1130-895-23
1130-895-93
1130-895-94
Start-up and parametrization software
Designation
Drive-Top
Drive- Help
Motion Manager
For controller/control system

DKC**.3
DKC**.3
CLM
Version
12VRS
06VRS
Part number
1135-400-12
1135-400-19
1135-200-01
Preassembled cables
Designation
Interface cable
I/O cable
Description/Use
PC 9-pin for DKC**.3, length 5 m
25-pin - for DKC01.3
22
Part number
1130-695-25
IN PREPARATION
RE 82 701/02.99
Documentation
Designation
For controller/control system
Part number
German
Project planning manual,

DKC**.3
Function description,
DKC firmware SMT
Function description,
DKC firmware FGP
DKC trouble-shooting,
DKC firmware SMT
DKC trouble-shooting,
DKC firmware FGP
Programming and
application manual, CLM
RE 82 701/02.99
English
All DKC**.3
1130-895-66
1130-895-69
DKC**.3 with analog, positioning, SERCOS and stepping

motor interface
1130-895-67
1130-895-70
DKC**.3 with Profibus-DP interface / field bus
1130-895-72
1130-895-74
DKC**.3 with analog, positioning, SERCOS and stepping

motor interface
1130-895-68
1130-895-71
DKC**.3 with Profibus-DP interface / field bus
1130-895-73
1130-895-75
CLM positioning control module
1130-895-44
1130-895-45
23
CD-Rom
German
English
In preparation

Electrical Connections - common to all controller models
DKC**.3-100-7-FW
DKC**.3-040-7-FW
X4 :
Encoder 1
X8:
Encoder 2
XS2: Cable clamp, shield terminations
X2:
RS232/RS485
Barcode
Barcode
5 6 7 8
L+
L+
Power connection
L-
XE2
1 2 3 4
DC link circuit connection
X5:
5 6 7 8
1 2 3 4
Motor temp. monitoring, holding brake
X6:
S2
S3
2
S2
H1
S1
H1
S1
Programming module (firmware, parameters)

H1 - Diagnosis display
S1 - Reset button
S2, S3 - Address switches
X7:
S3
Barcode
Typenschild
Controller-specific interface
Barcode
Typenschild
Control voltage supply and control

signals
10 11121314 1516 1718 5 6 7 8
X1:
1 2 3 4
1 2 3 4
Digital and analog inputs/outputs

1 2 3 4 5 6 7 8 9
10 11121314 1516 1718 5 6 7 8
1 2 3 4 5 6 7 8 9
X3:
L1
L2
XE1 L3
LL1
L2
XE1 L3
Motor connection
XE1: Protective conductor connection (motor)
XE2: Protective conductor connection (mains)
XE2
XS1: Cable clamp connection

for shields
- Overall shield, motor cable
- Holding brake
- Motor temp. monitoring
Motor cable
Mains power input
XS3: Cable U-clamp, shield connection

X11: Interface for connection to other STAR
drive families, DC link-circuit control,
drive synchronization
XS3
X11
X10: Expansion interface
X10
X9:
XS3
Incremental encoder / SSI emulation
X9
24
RE 82 701/02.99
Dimensions
Digital Controller DKC **.3-040-7
70
80
258
210
343
360
333
13
80
50
170
32.5
65
Digital Controller DKC **.3-100-7

110
52.5
7
343
360
333
9.5
13
80
258
210
80
50
171
22.5
60
52.5
105
20.5
10
10.5
10
L1
L1
40.5
N1
L1
60
40.5
50
50
RE 82 701/02.99
L2
L3
PE
79
PE
97
79
25
L2
L3
60
97
10.5
11
20.5
Mains filter 3 x 380 V, 10 A
11
Mains filter 1 x 230 V, 10 A
DKS Digital Positioning Module

Product Overview
The DKS digital positioning module is the cost-optimized solution for singleaxis drive and control functions.
Combined with MDD or MKD digital AC servomotors, it can be successfully
used wherever linear or rotary movements with power ratings of up to
8 kW have to be automated. With its outstanding performance data,
flexible operating modes and numerous application-oriented functions,
this automation module is the ideal control solution for applications
such as:
machine tools
handling equipment
assembly equipment
material feed conveyors
packaging machines
textile machines
printing machines
S1
H1
U1
U3
The DKS is a totally integrated package combining power supply and

motion control electronics into one space-saving module designed for
easy installation in a control cabinet and connection to the mains.
Slots to accommodate various plug-in modules for control, I/O and
measuring functions as well as the controller software enable the DKS
to be configured for universal use.
X17
X9
X8
By combining the DKS with highly responsive MDD or MKD AC servomotors, the user obtains an optimized control and drive system.
X2
U2
X7
DON'
T TO
CONN UCH EL
EC
VOLT ETIONS TRIC
AL
Elek AGE IS WHILE
tr.
AP
Verb Klemms PLIED
ind
bei an unge tellen un
liege n am Ge d
nd
nicht er Span rt
ber
nung
hren
MAIN
S/N
ETZ
U1
V1
U4
X3
DAN
G
HIG ER
H
VOLT
AGE
X17
DRIV
E/M
OTO
R
X6
W1
A1
A2
X4
A3
X24
DKS
Available complete with
control cabinet
26
RE 82 701/02.99
Compact construction
Integral DC link circuit short-circuit
Savings on
system components
Time-saving start-up
Built-in power contactor
Highly accurate speed and

positioning capability
MKD
MDD
Single-phase or three-phase
mains input
RE 82 701/02.99
Different power ratings available
27

Advantages
Single-phase or
three-phase mains input
Depending on the power ratings, direct
single-phase connection to 230 V or
three-phase connection to AC mains
through DST autotransformer or DLT
isolation transformer.
Single-phase mains connection to

230 V AC
for power ratings up to 2 kW
Three-phase mains connection to

3 x 230 V at any desired voltages
for power ratings up to 8 kW
L1
N
PE
L1
L2
L3
PE
Mains filter
Mains filter
DKS
DKS
Economical
Easily integrated
Safe
Compact construction
Units with different power ratings
Built-in starting interlock
For installation in control cabinets with

300 mm depth.
Available up to 3 kW, 5 kW and 8 kW.
Prevents unintentional restarts in accordance with the safety-at-work requirements

stipulated by professional trade associations.
Low-noise drive control

Time-saving initial start-up and
recommissioning
For units up to 3 kW due to 8 kHz cycle

frequency.
Achieved by the DDS2PC diagnosis program installed on PC or by the VT 100

terminal as well as exchangeable software
modules.
Integral DC link circuit short-circuit

This feature guarantees safe stopping of
the drive in the event of drive malfunctions.
Savings on system components

No additional position encoder required.
Internal holding brake control circuit

The power supply, control and monitoring
of the holding brake is handled directly by
the DKS.

Reduces the amount of wiring.
Due to the drive's internal position loop
with a cycle time of 250 s.
Comprehensive diagnostic facilities
Malfunctions are recognized quickly on the
diagnostic display on the DKS or through
the interfaces.
28
RE 82 701/02.99
Completely wired up in the control

cabinet
Available as a single-axis positioning unit
completely wired in the control cabinet,
with circuit diagram and documentation.
automatic mode, malfunction
mode
CTA keyboard for DLC positioning
interface installed in the control cabinet
door
S1
S1
7
H1
4
U1
U3
CR
CL
X17
X9
X8
X2
U2
X7
U4
DON'T
TOUCH
CONNE
ELECT
VOLTA TIONS
RICAL
Elektr. GE IS WHILE
Klemm APPLIE
Verbind
stellen D
ungen
bei anliege
und
am Gert
nder
nicht
Spannu
berhre
ng
n
MAI
NS /
U1
NET
V1

display elements
X3
DAN
GER
HIGH
VOLT
AGE
DRI
VE /
X17
MOT
OR
X6
W1
A1
RE 82 701/02.99
A2
A3
X4
X24
Deu
Sch tsche S
weinf tar G
mbH
urt
29

Plug-in interface modules
The DKS as a single-axis
positioning module with
digital drive control
Equipped with the following interfaces, the
DKS becomes an intelligent digital singleaxis positioning module. In many cases, an
additional PLC can be avoided altogether
by using the extensive functions integral
to these options:
DLC positioning interface
DEF incremental position interface
The positioning interface has a comprehensive set of commands allowing up to

3000 program blocks to be input into the
application program.
Programs can be structured with up to
127 subroutine levels. (Technical data and
programming commands can be found on
pages 32 and 33.)
This interface enables encoders to be

connected for direct detection of the
displacement or position of moving
machine parts.
Squarewave voltage signals from linear
scales or rotary encoders are resolved to
a factor of 4 and evaluated.
DEA digital I/O interface

Eight fixed and seven programmable
inputs plus five fixed and eleven programmable outputs are available with
this interface.
I/O expansion up to 45 inputs and
48 outputs is possible by installing
two additional (DEA) interfaces.
X1
X2
DLC
DEA
DEF
30
RE 82 701/02.99
Convenient program and parameter

input
The DKS is programmed by simply entering
up to 3000 program blocks. Each block
describes a sequence of motions or a
specific status of the monitored inputs or
the specified outputs.
The user-oriented programming language
identifies each control or monitoring
command by means of a three-character
code. The block can include data such as
the target position and the velocity.
After movement has begun, the DKS can
monitor the current sequence of motions
while simultaneously executing the next
program block.
One parameter block is used to match the

DKS to the mechanical and electrical conditions of a machine or system.
This parameter block is loaded into main
memory each time the DKS is powered up
and after exiting the parameter mode. The
system then checks if all parameters are
within their possible theoretical limits. An
error message appears if parameters are
missing or are outside the system limits.
Depending on the application requirements,

the DKS can be programmed and/or parametrized in various ways:
with the CTA programming keyboard,
with a master PC via the RS 232 interface, e.g. using the Motion Manager
PC program,
with the IDS decade switch unit via the
RS 232 interface,
with the SOT programming terminal via
the RS 485 interface,
or with a master PLC via the RS 232
interface.
RS 232
CTA
Motion Manager
Inbetriebnahmeprogramm
Internal bus, max. 30 m with unlit display

max. 10 m with lit display
RS 232, max. 15 m or RS 485, max. 1000 m
PC
I/O coupler
SOT
RS 485
SOT
RS 232
DKS
speed and
position sensing
Power
IDS
RS 232
PLC
MDD
RE 82 701/02.99
31
IDS

Technical Data for the DLC Positioning Interface
Controller details
Interfaces
Software
1 controllable axis
Units definable in mm, m, inches,
degrees, radians, etc.
Built-in absolute value encoder
Optional incremental encoder for direct
measurement
Programmable incremental or absolute
dimensions
Speed selection as % of vmax
Maximum system and manual speeds
programmable using parameters
Feedrate and zeroing speed programmable in the user program
Type 68000 microprocessor with 32-bit
format
Motion Manager PC program for

programming and parameter input to
the DLC positioning interface (optional)
Operating modes
Data interface:
- Serial: either RS 232 or RS 485
- Selectable transmission format
- Baud rate from 110 bps to 9600 bps
Parameter input, setup, automatic

Program data
Programs of up to 3000 blocks
Nesting of up to 127 subroutine levels
3 tasks possible
Display
Parallel interface:
8 system inputs and 5 system outputs
Machine functions:
7 inputs and 11 outputs, freely programmable in the user program
Input level:
On = 24 V DC
Off 1 V DC
Output level:
24 V DC
Imax = 100 mA
- Expandable up to 45 inputs and
48 outputs
Power ratings
Modules with power ratings up to 3 kW,
5 kW or 8 kW
Environmental conditions
Ambient temperature: 5 C to 45 C
Storage temperature: - 30 C to 85 C
Controller interface:
built in
Measuring system interface:

- Built into drive: absolute-value
encoder
- For linear or rotary incremental
encoders:
1 MHz maximum sampling frequency
Two-digit diagnostic display

Choice of languages for CTA:
German, English, French, Spanish,
Italian or Portuguese
32
RE 82 701/02.99
Programming Commands / Software

Feed commands
Input and output commands
POI
Incremental feed with immediate progression to next block
AEA
Switch output on/off
PSI
Incremental feed with progression to next block on reaching target

position
AKN
Interrogate input status
APE
Set 10 outputs simultaneously
POM
Incremental feed via IDS decade switch unit or via inputs, with immediate
progression to next block
ATS
Interrogate output status
PSM
Incremental feed via IDS decade switch unit or via inputs, with
progression to next block on reaching target position
AKP
Interrogate status of 10 inputs simultaneously
CIO
Copy I/O status
APJ
Set 10 outputs with program branching
POA
Absolute feed with immediate progression to next block
PSA
Absolute feed with progression to next block on reaching target position
CON
Continuous running of an axis
ACC
Change acceleration
VCC
Change velocity
HOM
Move axis to home position
REF
Move axis to reference point (search)
REP
Limitation of search path for moving to reference point
FOL
Follower axis; slave axis performs all motions synchronously with

master axis
PST
Position check
PBK
Termination of positioning cycles
COC
Cam control; 6 outputs are switched according to current position
Counter commands
Jump to subroutine
RTS
Return from subroutine
JMP
Jump to a program line
JST
Jump to a program line and then stop the program
BCA
Jump with output logic gating
BMB
Execute block with output logic gating
BCB
Jump to calculated target block with binary input setting
BCD
Jump to calculated target block with decimal input setting
BCE
Jump with input logic gating
BPE
Jump with logic gating of 10 inputs
BIO
Jump with input and output logic gating
BPA
Jump with logic gating of 10 outputs
BPT
Jump on reaching target axis position
BZP
Jump at position overrun
CST
Clear subroutine stack
Input example:
PSA 1 + 002500.00 600
Axis 1 will be positioned to absolute position 2500.00
mm at 600 of the maximum velocity selected. Once
the axis is in position, the program moves to the next
command block.
Motion Manager software

The control system can be started up without any additional software.
If required, however, the Motion Manager software package (part
number 1135-200-01) can be supplied as an option for convenient
programming, data backup and program optimization.
RE 82 701/02.99
Jump with workpiece count
COU
Count
CLC
Reset counter
Miscellaneous commands
Jump commands
JSR
BAC
33
WAI
Wait for set time delay
NOP
Blank line, no operation
SCA
Setup axis to a new absolute position
STH
Send to host computer
CLA
Clear absolute positioning
FAK
Multiplication factor
SO1
Read in position information via selector switches or PLC
SO2
Correct a position via analog input
VEO
Velocity override
WRI
Store an absolute position value
KDI
Copy position difference

Plug-In Interface Modules
The DKS as a Drive Control
Module with Analog Interface
When fitted with an analog interface, the
DKS can be used as a digital drive control
module for communication with control
systems that have a 10 Volt interface.
The following features distinguish the DKS
with analog interface from conventional
drives:
The drive control module directly

controls and monitors the holding
brake.
Two drive operating modes:
Speed control
Torque control
Analog interface with DAE

incremental encoder emulator
The current axis position is indirectly
detected via the digital servo feedback
or resolver feedback in the motor and
processed in the drive control module.
The relative axis position is output to the
control system via this interface in the
form of squarewave incremental encoder
signals. The number of encoder lines can
be set via parameters.
Analog interface with DAA
absolute-value encoder emulator
The rotor position can be output to the

control system either as an incremental
encoder signal or an absolute-value
encoder signal.
The current axis position is indirectly detected via the absolute digital servo feedback or the absolute resolver feedback in
the motor and processed in the drive control module.
The absolute axis position is output to the
control system via this interface in the
form of absolute-value encoder signals
in Gray code and SSI format.
Problem-free matching of position

encoder signal resolution to different
machine and control system conditions.
The drive's internal speed control
ensures drift-free stopping.
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
X1
4
X1
0
DAE
DAA
34
RE 82 701/02.99
The DKS as a Drive Control

Module with SERCOS Interface
When fitted with the SERCOS interface the
DKS can be used as a digital drive control
module for communication with SERCOScompatible control systems.
DSS SERCOS interface

This digital interface enables all the facilities and benefits of digital AC drive technology to be fully utilized.
For example:
Four pre-selectable drive modes that
can be alternated during operation:
Position control with indirect
position detection in the motor,
with or without lag error.
Position control with direct position detection via linear scale or
rotary encoder in the case of rotary
indexing tables, with or without
lag error.
Speed control
Torque control
Interference-free data exchange between control systems and drives of
different manufacture via fiber-optic
cables.
CH
X2
X2
1 2 3 4 5 6 7 8 9
DSS
RE 82 701/02.99
DLF
DEF
35
Input and display of all internal drive

data, parameters and diagnostics via
the control system.
Savings on control system complexity,
cable connections and position
encoders.
DLF high-resolution position interface
This interface enables encoders to be connected for direct detection of the displacement or position of moving machine parts.
Sinewave current signals from linear scales
or rotary encoders are resolved to a factor
of 2048 and evaluated.

Performance Data
MKD motor with DKS Positioning Module
Mains input 3 x 230 V AC
Motor
Controller OF
nmax MdN
Mmax - n100 - n90
JM
JB
mM
MBr
(%)
(Nm)
(%)
(kg)
(kg)
(Nm)
(kVA)
220
200
207
6200
5100
5100
0.8
2.7
2.7
3.4 8152 7032

9.9 4327 3705
11.0 4111 3489
2.4
5.8
5.8
1.2
2.6
2.6
1.6
5.2
5.4
25
27
25
0.3
1.7
1.7
0.08
0.16
0.16
2
4.4
4.4
0.25
0.25
0.25
1
2.2
2.2
0.56
0.83
0.83
071B-097 W050A
071B-097 W050A
071B-097 W100A
154
110
207
3600
3600
3600
8.0
8.0
8.0
12.8 3650 3314

18.7 3386 2924
32.0 2499 2037
15.4
15.4
15.4
8.5
8.5
8.5
11.6
8.5
15.4
47
90
27
8.7
8.7
8.7
0.38
0.38
0.38
8.8
8.8
8.8
0.37
0.37
0.37
5
5
5
1.55
1.55
1.55
090B-085 W100A
090B-085 W100A
144
200
3200 12.0
3200 12.0
39.6 2017 1642

29.2 2473 2098
12.6
12.6
4.0
4.0
16.9
23.6
51
26
43.0
43.0
1.10
1.10
0.65
0.65
11
11
2.21
2.21
(Nm) (Nm)
(kgcm2)
mB
DKS1.1-
(Nm) (Nm)
(min-1)
MKB - DC
025B-144 W030B
041B-144 W030B
041B-144 W050A
MKD
(min-1)
M100 - M90
(min-1)
14
14
MDD motor with DKS Positioning Module

Motor
Controller OF
MDD
DKS1.1-
nmax
MdN
065B-N-060
W030B
220
4700
1.5 1.71)
4.4 3868 3271
2.6
1.4
2.8 29 381)
2.2 0.38
3.9 0.55
0.6
0.71)
071A-N-060
071A-N-060
W030B
W030B
220
201
3800
3800
2.2
2.2
6.0 3192 2693

6.4 3084 2585
4.0
4.0
2.3
2.3
4.4 25
4.1 29
4.4 0.38
4.4 0.38
6.5 0.3
6.5 0.3
3
3
0.7
0.7
071C-N-040
071C-N-040
W030B
W030B
137
110
2500
2500
6.6 8.81)2) 8.8 2706 2375

8.8
6.6 7.21)2) 11.8 2505 2175 11.8
7.0
7.0
8.8 56 1001) 11.9 0.38 11

7.2 83 1001) 11.9 0.38 11
0.3
0.3
3
3
1.2
1.2
1.91)
1.91)
mB
MBr
(%) (min-1) (Nm) (Nm)
Mmax - n100 - n90 M100 - M90 MKB - DC - DC

(Nm) (min-1) (min-1) (Nm) (Nm) (Nm) (%) (%)
JM
JB
(kgcm2)
mM
mB
MBr
(kg) (kg) (Nm)
S
(kVA)

Motor
MDD
Controller
DKS1.1-
nmax
(%)
(min-1)
MdN
(Nm) (Nm)
Mmax - n100 - n90 M100 - M90 MKB - ED - ED

(Nm)
(min-1) (min-1)
(Nm) (Nm) (Nm) (%) (%)
JM
JB
(kgcm2)
mM
(kg) (kg) (Nm)
S
(kVA)
065B-N-060
W030B
220
6000
1,5
1,71)
071A-N-060
071A-N-060
071A-N-060
W030B
W030B
W050A
220
201
220
5300
5300
5300
2,2
2,2
2,2
071C-N-040
071C-N-040
071C-N-040
071C-N-040
071C-N-040
W030B
W030B
W050A
W050A
W100A
137
110
205
137
220
3500
3500
3500
3500
3500
6,6
6,6
6,6
6,6
6,6
8,81)2)
7,21)2)
9,91)
8,81)2)
9,91)
11
11
11
11
11
0,3
0,3
0,3
0,3
0,3
3
3
3
3
3
1,2
1,2
1,2
1,2
1,2
1,91)
1,91)
1,91)
1,91)
1,91)
090C-N-030
090C-N-030
090C-N-030
W050A
W050A
W100A
154
110
200
3000 10,4 15,01)2) 15,0 3000 3000 15,0 15,0 15,0 48 1001) 53,0 1,06 23
3000 10,4 10,71)2) 23,5 3000 2854 23,5 19,5 10,7 95 1001) 53,0 1,06 23
3000 10,4 16,01) 50,0 2299 1886 30,8 19,5 19,4 29 681) 53,0 1,06 23
0,5
0,5
0,5
11
11
11
1,7
1,7
1,7
2,71)
2,71)
2,71)
093C-N-030
093C-N-030
W100A
W100A
186
124
2900 19,5 20,81)

2900 19,5 20,81)
1,1
1,1
11
11
2,8
2,8
3,01)
3,01)
4,4 5860 5063
4,1
2,4
6,0 4856 4191

6,4 4748 4083
6,8 4604 3939
4,5
4,5
4,5
2,3
2,3
2,3
8,8
11,8
12,4
17,4
20,5
3807
3607
3562
3223
3013
3366
3166
3121
2783
2573
8,8
11,8
12,4
13,4
13,4
2,8 29
381)
2,2 0,38
3,9 0,55
0,6
0,71)
4,4 25
4,1 29
4,4 25
4,4 0,38
4,4 0,38
4,4 0,38
6,5 0,3
6,5 0,3
6,5 0,3
3
3
3
0,7
0,7
0,7
6,9 8,8 56 1001)

6,9 7,2 83 1001)
6,9 12,4 28 641)
6,9 8,8 56 1001)
6,9 13,1 25 571)
11,9
11,9
11,9
11,9
11,9
34,0 2900 2653 34,0 17,6 34,0 33 371) 42,0

48,8 2784 2433 41,0 17,6 23,9 67 751) 42,0
0,38
0,38
0,38
0,38
0,38
3,6 22
3,6 22
The maximum torque Mmax must be limited to the maximum permissible torque of the mechanical structure.
1)
2)
Air-cooled motor
Limited to MKB due to controller continuous current rating
36
RE 82 701/02.99
Key to symbols used
RE 82 701/02.99
OF
nmax
MdN
Mmax
-n100
-n90
M100-M90
MKB-DC-DC
JM
JB
mM
mB
MBr
S

Motor mass
Brake mass
Connected power
37

Ordering Data and Dimensions
Part number 1130-211-10 DKS Digital Positioning Module
Power section =
DKS 1.110
W030B
14
02
DKS 1.111
W050A
15
04
DKS 1.112
W100A
16
11
DAA
12
DLC DEA
13
DLC DEA DEA
14
11
21
15
25
16
26
CD-ROM
D
E
11
00
DLC DEA DEA DEA 15

DSS
Motion
Manager
for DLC
without
U4
DAE
without
without with
English
E
02
U1
Slot
U2 U3
German
D
01
Documentation
DKS controller =
DDS2PC
1x
3x
230 V 230 V~
via autotransformer
Configuration =
Control Controller
Control
soft(plug-in interface
cabinet =
system
modules with
(completely ware =
software =
connection accessories)
wired)
without
Resolver feedback R
Feedback
for motor
Digital servo
feedback D
Power
supply =
12
00
01
00
01
00
31
41
13
16
Further configurations, combinations and options, e.g. external control desk,

decade switch, displays and customized programs, can also be supplied.
Motor and feedback cable to DKS
Motor assignment
MKD 025B-144
Preassembled cable options

Motor side
Controller side
with connector
without connector
for DKS
1130-001-17,
01
40
MKD 071B-097
1130-001-15,
02
41
MKD 090B-085
1130-001-40,
03
42
MDD 065B-N-060
MDD 071A-N-060
1130-001-17,
04
43
MDD 071C-N-040
1130-001-15,
05
44
MDD 090C-N-030
1130-001-25,
06
45
MDD 093C-N-030
1130-001-40,
03
42
MKD 041B-144
Ordering example
Part number,
Length in m
(max. 75 m)
Ordering data
Explanation

Power connections
= 02
Power section
= 15
Configuration
= 14
Control cabinet
= 12
Controller software
= 00
Control system
software
= 01
DKS Documentation
= 15
38

Three-phase connection via autotransformer
Power section DKS 1.1-W050A with 50 A rated
current for operation of an MDD motor with
digital servo feedback
DLC positioning interface with two DEA I/O
boards
Completely wired control cabinet with operating
controls and displays in control cabinet door
Without controller software
Motion Manager PC program for programming
and parametrizing the DLC positioning interface
Documentation for DKS with DLC (German)
RE 82 701/02.99
Dimensions
CTA 4
170
Cooling air outlet
Min. clearance
80 mm
21
6
10
143
182
390
355
203
35
260
ax
.R
125 +0.2
92.5
4.6 +0.2
185
190
92.5
185
210
Cooling air inlet
Min. clearance
80 mm
125
X1
115+0.4
107
Mounting cutout
max. perm. panel thickness
5 mm
Control cabinet
600
H (mm)
11
12. 13
760
1000
Control cabinet options
350 mm deep
RE 82 701/02.99
39
DDS Digital Controller with CLM Analog Positioning Module

Product Overview
The digital AC servo drive system sets new standards in terms of dynamic
response, smooth running and positioning accuracy. Its decentralized
intelligence facilitates additional functions, such as linear interpolation
and an electronic cam function.
High power density and a selective axis shutdown, approved by professional
trade associations, are further features of this drive system.
Maximum feedrates due to a precisely matched combination of:
Power supply module with direct mains connection and mains

regeneration capability
Digital drive controller
Servomotors with digital servo or resolver feedback
Power supply module with

direct mains connection
Effective drive monitoring and diagnostics significantly speed up start-up

procedures and boost system availability. Furthermore, installation is greatly
simplified as no separate position encoders and connection cables are required.
X7
Combined with a CNC control system, this equipment can master complex motion
sequences.
DA
NG
ER
HIG
HV
OL
TAG
E
A1
LDO
TR NT
ICAL TO
UC
SW FOR CONNH EL
ITCH 5 MI EC EC
ING N AF TION
PO TER S
WER
OF
F
D
A2
Attention: Max. Drehmoment/Torque: M5 = 3Nm, M6 = 5Nm
For optimum use, digital drives require a digital interface to the CNC control
system. Digital AC servo drives from Star can be equipped with such an interface.
AN
G
HIG ER
VO H
El
LTA
ein ektr.
nic geschaAnsc
GE
ht be lte hl
Absc
rhr tem sse im
Entlahalteen. NaZusta
dezen erst ch dend
it ab 5 mi m
wa n
rten
L+
X9
A3
LPO
WE
RS
UP
PLY
VO H
El
LTA
ein ektr.
nic geschaAnsc
GE
ht be lte hl
Absc
rhr tem sse im
Entlahalteen. NaZusta
dezen erst ch dend
it ab 5 mi m
wa n
rten
X5
RE
SE
AT
TE
NT
VE IO
NE
DIG
ITA
L
N!
R
UG REMO
S
AC WH VE
Ve K CA ILE OR INS
rbi
BL VO
ls ndun E LTA TALL
ON GE
en
g
Sc bzw. nie un TH IS APTHIS
E
hw
BO
PL
arz stecke ter
Sp
IED
TT
e Le
an
OM
.
itu n.
nu
ng
ng !
im
me
r un
ten
!
PL
BL
S2
ZK
S
ZK
S
AU
berhnder rbind
ren Span unge
!
nung n
U1
S
AU
S
EIN
EIN
U4
2
3
4
1 2 3 4 5 6 7 8 9 10
Bb1
Bb1
UD
UD
BV
W
BV
W
TV
W
TV
W
X1
0
Variable number of axes
TVD
DDS 2
Multiple diagnostic
capabilities
Different power ratings

available
40
CO
NTR
OLL
ER
U3
+24V
0V
X5
Span
is nu
nacholatio ngsDINnsgeprund
VD ft
E 01
60
U2
NC
B
NC
B
+15V
0V
M
-15V
K1N
C
K1N
C
K1N
O
K1N
O
U5
DO
TR NT
ICAL TO
UC
SW FOR CONNH EL
ITCH 5 MI EC EC
ING N AF TION
PO TER S
WER
OF
F
D
AN
G
HIG ER
L+
Span
iso nu
nachlationngsDIN sgepund
VD rft
E 01
60
DO
NT
CO TOUC
NN
Ele VOLT ECTIH EL
EC
ktr
am . Kle AGE ONS TR
IC
Ge mm
rt ste IS APWHILEAL
bei llen
PL
nic anliegeund Ve IED
ht
H1
RE 82 701/02.99
Built-in starting interlock
Available complete with control cabinet
Savings on system
components
H1
X5
D
TR ONT
ICAL TO
U
SW FOR CONCH EL
ITC 5 M NEC EC
HIN IN TIO
G POAFTE NS
WERR
OFF
D
CL
AN
G
HIG ER
VO H
El
LTA
eingektr.
nich eschAnschl
GE
t be alte sse
Absc
rhr tem im
Entlahalteen. N Zustan
dezen erstach de d
it ab 5 m m
war in
ten
AT
TE
NE NT
VE IO
PL R RE N!
UG
MO
BL S WH VE
AC
Ve K CA ILE OR INS
rbi
BL VO
ls ndun E LTA TALL
ON GE
en
g
bz nie
TH IS TH
hw w. ste unter E BO AP IS
PL
arz
e Le cke Span TTOM IED
.
itu n.
nu
ng
ng !
im
me
r un
ten
!
Sc
U2
U1
1 2 3 4 5 6 7 8 9 10
CL
CR
Time-saving start-up
X1
0
SW
IT
BE CH
FO
MO RE OFF
DU CH VO
AN LTAG
Mod LE
GIN E
Sp ul ni
G
an ch
nu t un
ng
we ter
ch
se
ln
HOK
11
HA
RD
WAR
CLM
1
E:
01.
SO
FT
WAR
E:
LA
01.
2-0
02.
10
1
1 12 1
31
41
DDS 3
CLM
Extensive range of
interfaces available
RE 82 701/02.99
MDD
41
DDS Digital Controller

Interfaces
Positioning Interface
Analog interface
DDS controllers can be fitted with the DLC

positioning interface. (For a description of
the DLC, see DKS page 30.)
The following features distinguish digital

AC servo drives with analog interface from
conventional analog drives:
The controller transmits the rotor position to the NC control system as a
position actual value, either as an
incremental encoder signal or an
absolute-value encoder signal.
The position encoder signal resolution
can be parametrized to match different
machine and control system conditions.
A switching input ensures drift-free
stopping of the digital drive.
For 2-axis (or optionally 4-axis) systems,
the analog interface can be used to run
the proven CLM positioning module.
CNC control system

(position control loop) e.g., CLM
Analog interface with DAE

incremental encoder emulator
The current axis position is indirectly detected via the digital servo feedback in the
motor and processed in the drive control
module.
The relative axis position is output to the
control system via this interface in the form
of squarewave incremental encoder signals.
The number of encoder lines can be set via
parameters.
Analog interface with DAA
absolute-value encoder emulator
The current axis position is indirectly
detected via the absolute digital servo
feedback or the absolute resolver feedback
in the motor and processed in the drive
control module.
The absolute axis position is output to the
control system via this interface in the form
of absolute-value encoder signals in Gray
code and SSI format.
DDS digital controller

with analog interface
MDD
servomotor
+W
Kv
Analog
speed
command
D
A
10 V
M
3~
A
D
~~
-X
Position
interface
High-resolution
position interface
Position
actual
value
Linear scale
42
RE 82 701/02.99
DSS SERCOS interface
DLF high-resolution position interface
This digital interface enables all the facilities

and benefits of digital AC servo drive technology to be fully utilized.
For example:
Sinewave current signals from linear scales
or rotary encoders are resolved to a factor
of 2048 and evaluated.
The SERCOS permits interference-free

interaction between control systems and
drives of different manufacture via fiberoptic cables.
The SERCOS interface provides four preselectable drive modes that can be alternated during operation:
Position control with indirect position
detection in the motor, with or without lag error.

Position control with direct position

detection via linear scale or rotary
encoder in the case of rotary indexing
tables, with or without lag error.
Speed control
Torque control
CNC control system
DDS digital controller

with SERCOS interface
MDD
servomotor

SERCOS
interface
SERCOS
interface
M
3~
~~
High-resolution
position interface
High-resolution
position interface
Linear scale
RE 82 701/02.99
43

Advantages
Economical
Savings on system components
Safe
Extensive product range
The drive's internal high-resolution

position sensing and control capabilities eliminate the need for separate
position encoders, interfaces and
connection cables.
Safe selective shutdown
For almost every customer-specific application, the optimum technical and economical solution can be achieved by utilizing
the following components:
Power supply modules with direct mains
connection and mains regeneration,
available with internal or external
cooling.
DDS drive controllers with different
power ratings, available in 2 different
frame widths.
MKD or MDD servomotors with a continuous torque range from 0.15 Nm
to 88 Nm and a speed range from
1500 min -1 to 10,000 min -1.
Power supply modules designed for

direct connection to international
three-phase AC mains ranging from
380 V/50 Hz to 460 V/60 Hz eliminate
the need for mains transformers.
Built-in power contactor and safety
shutdown.
Easily integrated
Convenient and rapid start-up
User-friendly data input and display
directly on the NC terminal.
High-quality, high-speed machining

Precision feeding and a high degree
of accuracy together with position
repeatability provided by the drive's
internal position control achieving a
resolution of 1/2,000,000 revolutions
with digital servo feedback.
Position control without additional position encoder, or via linear scale on the
machine.
Exceptionally high contouring accuracy
at high-speed point-to-point travel due
to fine interpolation and lagless internal
position control with a cycle time of
250 s.
NC-independent start-up using a

graphic-based PC program.
The starting interlock built into the drive

controllers is a safety function approved by
professional trade associations. This makes
it possible to secure individual motors in
physically separated work areas against
unintentional start-up after stopping to
protect persons present in the danger zone.
For the user, this results in the following
advantages:
Controllers for separate work areas can
be powered by one single power supply
module.
No need for motor contactors in the
motor supply cables.
Controlled motor braking in the event of
a mains power cut.
Individual axes can be driven separately
in setup mode.
Easy adaptation to different machines

and control systems by means of parameter input.
Rapid diagnosis of all operating statuses
provided by displays with clear text messages for localization and elimination of
any malfunctions.
Rapid initial start-up and recommissioning of standard machines by loading
complete parameter sets.
Enhanced surface quality due to low

torque ripple factor, high position resolution and short position loop cycle
times.
Linear scales with 0.02 mm measuring
grids are scanned with 0.01 m resolution up to 180 m/min feedrate.
Parameters are used to match the controllers to different drive mechanisms
(gears, screw leads, etc.) and adapt
command and actual values to the
installed control system.
44
RE 82 701/02.99
Completely wired up in the

control cabinet with CLM
control module
Available as a positioning unit completely
wired in the control cabinet, with circuit
diagram and documentation.
automatic mode, malfunction
mode
X7
DA
NG
ER
HIG
H VO
LTA
GE
A1
CL
LDONT
TRICAL
TOUCH
FOR CONNE
SWITCH
ELEC
5 MIN CTIONS
ING AFTER
POWER
Attention: Max. Drehmoment/Torque: M5 = 3Nm, M6 = 5Nm
A2
OFF
DANG
HIGHER
Elektr. VOLT
eingesc
Anschl AGE
nicht haltetem
berhre sse
Abscha
im
Zustand
Entladeltenn. Nach
zeit erst 5 dem
abwarte
min
n
L+
X9
A3
LPOW
ER
SUP
PLY
4
1
TOUCH
FOR CONNE
SWITCH
ELEC
5 MIN CTIONS
ING AFTER
POWER
H1
OFF
DANG
HIGHER
L+
X5
ZKS
ZKS
AUS
AUS
EIN
NEVER
ION!
R OFF
DAN
GER
HIG
ROLL
ER
U2
U3
ATTENT
NEVER
U4
2
3
4
Bb1
UD
UD
BVW
BVW
TVW
TVW
ION!
PLUGS REMOVE
BLACK WHILE
VerbinduCABLE OR
INSTALL
VOLTAG
lsen ng
ON
E
bzw. nie
THE IS THIS
Schwarze
unter
APPLIED
stecken.
BOTTOM
Spannun
Leitung
.
!
g
immer
unten!
1 2 3 4 5 6 7 8 9 10
Bb1
1
X5
Elektr. VOL H
einges
Ansch TAG
nicht chalte
E
berhr temlsse
Absch
im
Zustan
Entladaltenen. Nach
d
ezeit erst dem
5 min
abwar
ten
CONT
unten!
U1
+24V
0V L
K1NC
K1NC
K1NO
K1NO
CL
DONT
TRICA
TOUC
FORL CONNH
SWITC
ELEC
5 MIN ECTIO
HING
AFTER
POWE NS
DIGIT
AL
PLUGS REMOVE
BLACK WHILE
VerbinduCABLE OR
INSTALL
VOLTAG
lsen ng
ON
E
bzw. nie
THE IS THIS
Schwarze
unter
APPLIED
stecken.
BOTTOM
Spannun
Leitung
.
!
g
immer
S2
EIN
NCB
NCB
+15V
0V
M
-15V
CLM keyboard for positioning control

module installed in the control cabinet
door
Spann
isolatioungsnach
DINnsgepund
VDE rft
0160
ATTENT
RES
ET
DONT
TOUCH
CONNE
Elektr. VOLTAGCTIONS
ELECTR
am Klemmst E
ICAL
Gert
IS WHILE
bei ellen APPLIE
anliegen
und
D
nicht
Verbindu
berhren
der
Spannun
ngen
!
g
X5
A
Elektr. VOLT
eingesc
Anschl AGE
nicht haltetem
berhre sse
Abscha
im
Zustand
Entladeltenn. Nach
zeit erst 5 dem
abwarte
min
n
Spannu
isolatio
nach ngsDINnsgeprund
VDE ft
0160
U1
U2
X10
1 2 3 4 5 6 7 8 9 10
X10
SWITC
BEFORH
MODU E OFF
CHANVOLTA
Modul LE
GING GE
Spann nicht
ung unter
wechs
eln
HOK
11
De
Sc utsc
hw he
ein S
furttar
HARD
WARE
:
CLM
01.2
1
Gm
bH

display elements
RE 82 701/02.99
7
H1
U5
DONT
TRICAL
45
SOFTW
LA
5
ARE:
01.2
-002
.1
8
10
11
12
13
14
15
8
5
2
0
CR
9
6
3
-
CLM Controller
Technical Data
Control module details
Interfaces
Power supply
2 axes (4 axes optional)

Linear interpolation
Units definable in mm, m, inches,
degrees, radians, etc.
Programmable incremental or
absolute dimensions
Speed selection as of vmax
Maximum system and manual speeds
programmable using parameters
Feedrate and zeroing speed programmable in the user program
Microprocessor with 32-bit format
Parallel interface:
16 system inputs and 16 system
outputs
+24 V DC; +/-20%, 1.5 A supplied by

internal drive electronics
Operating modes
Parameter input, setup, automatic
Program data
Programs of up to 3000 blocks
Nesting of up to 127 subroutine levels
Display
Four-line LCD
Choice of languages: German,
English, French, Spanish, or Italian
Machine functions:
16 inputs and 16 outputs, freely
programmable in the user program
Expandable up to 80 inputs and
48 outputs (optional)
Input level:
On = 24 V DC
Off 1.5 V DC
Output level:
24 V DC
Imax = 50 mA
per output
Controller interface:
4 analog inputs 10 V
2 analog outputs 10 V for
actuation of 2 servo drives
4 analog outputs 10 V for
actuation of 4 servo drives (optional)
Data interface:
Serial: either RS 232, RS 422 or
RS 485
Selectable transmission format
Baud rate from 110 bps to
19,200 bps
Cooling method: natural convection

Protection class: IP10
Ambient temperature:
5 C to 45 C
Storage temperature: - 30 C to 85 C
Maximum operating altitude: 1000 m
Programming and parameter input

The program, parameters and data can be
input into the CLM in various ways:
with the 20-digit CLM membrane
keyboard
with the SOT intelligent programming
terminal (optional)
with the IDS decade switch unit or
decade switches (optional)
with an intelligent unit such as PC
or PLC
The Motion Manager software package
can be supplied (as an option) for convenient programming, parameter input and
data backup using a commercially available
AT or XT PC.
Measuring system interface:

For linear or rotary incremental encoders: 1 MHz maximum sampling
frequency
For synchronous absolute-value encoders: synchronous serial transfer in
Gray code, 250 kHz clock frequency
46
RE 82 701/02.99
Programming Commands / Software

Feed commands
Input and output commands
POI
Incremental feed with immediate progression to next block
AEA
Switch output on/off
PSI
Incremental feed with progression to next block on reaching target

position
AKN
Interrogate input status
APE
Set 10 outputs simultaneously
POM
immediate progression to next block
ATS
Interrogate output status
PSM
progression to next block on reaching target position
AKP
Interrogate status of 10 inputs simultaneously
CIO
Copy I/O status
APJ
Set 10 outputs with program branching
POA
Absolute feed with immediate progression to next block
PSA
Absolute feed with progression to next block on reaching target

position
CON
Continuous running of an axis
ACC
Change acceleration
BAC
Jump with workpiece count
Change velocity
COU
Count
Move axis to home position
CLC
Reset counter
VCC
HOM
Counter commands
REF
Move axis to reference point (search)
REP
Limitation of search path for moving to reference point
Miscellaneous commands
FOL
Follower axis; slave axis performs all motions synchronously with

master axis
WAI
Wait for set time delay
Position check
NOP
Blank line, no operation
Termination of positioning cycles
SCA
Setup axis to a new absolute position
Cam control; 6 outputs are switched according to current position
STH
Send to host computer
CLA
Clear absolute positioning
PST
PBK
COC
FAK
Multiplication factor
Jump commands
SO1
Read in position information via selector switches or PLC
JSR
Jump to subroutine
SO2
Correct a position via analog input
Return from subroutine
VEO
Velocity override
JMP
Jump to a program line
WRI
Store an absolute position value
JST
Jump to a program line and then stop the program
KDI
Copy position difference
BCA
Jump with output logic gating
RTS
BMB
Execute block with output logic gating
BCB
Jump to calculated target block with binary input setting
BCD
Jump to calculated target block with decimal input setting
BCE
Jump with input logic gating
BPE
Jump with logic gating of 10 inputs
BIO
Jump with input and output logic gating
BPA
Jump with logic gating of 10 outputs
BPT
Jump on reaching target axis position
BZP
Jump at position overrun
CST
Clear subroutine stack
Input example:
PSA 1 + 002500.00 600
Axis 1 will be positioned to absolute position 2500.00
mm at 600 of the maximum velocity selected. Once
the axis is in position, the program moves to the next
command block.
Motion Manager software

The control system can be started up without any additional software.
If required, however, the Motion Manager software package (part
number 1135-200-01) can be supplied as an option for convenient
programming, data backup and program optimization.
RE 82 701/02.99
47

Performance Data and Dimensions
MKD motor with DDS Controller
MKD selection data for DDS 2 and DDS 3 controllers with unstabilized DC link circuit voltage (TVM)
Motor
Controller OF
MKD
DDS-
025B-144
041B-144
041B-144
041B-144
1.1-W030
3.1-W030
3.1-W030
3.1-W030
nmax MdN
3.1-W050
3.1-W050
2.1-W100
2.1-W100
2.1-W150
M100 - M90
MKB - DC
(Nm
(Nm) (%)
220
133
200
207
1.2
2.6
2.6
2.6
1.6
3.6
5.2
5.4
6200
5100
5100
5100
071B-097 3.1-W050 103 3600

071B-097 2.1-W100 207 3600
090B-085
090B-085
090B-085
090B-085
090B-085
Mmax - n100 - n90
(%) (min-1) (Nm) (Nm) (min-1) (min-1) (Nm
72
144
144
200
200
3200
3200
3200
3200
3200
0.8 3.4
2.7 9.9
2.7 5.2
2.7 11.0
8152
5100
5100
4111
7032
3705
4598
3489
8.0 19.2 3348 2886

8.0 32.0 2499 2037
12.0
12.0
12.0
12.0
12.0
21.3
21.3
39.6
29.2
48.0
2819
2819
2017
2473
1648
2444
2444
1642
2098
1273
2.4
5.8
5.8
5.8
JM
JB
(kgcm2)
mM
mB
MBr
PBM
PDC
(kg)
(kg)
(Nm)
(kW)
(kW)
25
57
27
25
0.3
1.7
1.7
1.7
0.08
0.16
0.16
0.16
2
4.4
4.4
4.4
0.25
0.25
0.25
0.25
1
2.2
2.2
2.2
0.56
3.5
2.31
3.62
2.90
1.44
1.44
1.44
15.4 8.5
15.4 8.5
7.9 100
15.4 27
8.7
8.7
0.38
0.38
8.8
8.8
0.37
0.37
5
5
5.9
8.3
2.98
3.02
12.6
12.6
12.6
12.6
12.6
8.7 100
16.9 51
16.9 51
23.6 26
23.6 26
43.0
43.0
43.0
43.0
43.0
1.10
1.10
1.10
1.10
1.10
14
14
14
14
14
0.65
0.65
0.65
0.65
0.65
11
11
11
11
11
5.78
5.78
8.37
7.34
8.6
2.92
4.02
4.02
4.02
4.02
4.0
4.0
4.0
4.0
4.0
MDD motor with DDS Controller

MDD selection data for DDS 2 and DDS 3 controllers with unstabilized DC link circuit voltage (TVM)
Motor
Controller
MDD
DDS-
OF
nmax
MdN
Mmax - n100 - n90
(%) (min-1) (Nm) (Nm)
M100 - M90
MKB - DC -DC
(Nm )(min-1)(min-1) (Nm) (Nm) (Nm) (%) (%)
JM
JB
(kgcm2)
mM mB MBr
PDC
(kg) (kg) (Nm) (kW) (kW)
065B-N-060 3.1-W030 220 6000

065B-N-060 3.1-W030 192 6000
065B-N-060 3.1-W050 220 6000
1.5 1.71)
1.5 1.71)
1.5 1.71)
3.8 6000 5329

4.4 5860 5063
4.4 5860 5063
3.8
4.1
4.1
2.4
2.4
2.4
2.8 29 371)
2.5 36 461)
2.8 29 371)
2.2 0.38 3.9 0.55

2.2 0.38 3.9 0.55
2.2 0.38 3.9 0.55
3
3
3
0.3 0.391)
0.3 0.391)
0.3 0.391)
071A-N-060 3.1-W030 200 5300

071A-N-060 3.1-W030 133 5300
071A-N-060 3.1-W050 220 5300
2.2
2.2
2.2
4.0 5300 4784

6.3 4774 4109
6.7 4634 3968
4.0
4.5
4.5
2.3
2.3
2.3
4.0 30
2.9 60
4.3 26
4.4 0.38 6.5 0.3

4.4 0.38 6.5 0.3
4.4 0.38 6.5 0.3
3
3
3
0.4 0.4 0.4 -
071C-N-040 3.1-W050 137 3500

071C-N-040 2.1-W100 220 3500
6.6 8.81)2) 17.4 3227 2786 13.4

6.6 9.91) 20.5 3017 2576 13.4
0.3
0.3
3
3
0.8 1.281)
0.8 1.281)
6.9 8.8 56 1001) 11.9 0.38 11

6.9 13.1 26 571) 11.9 0.38 11
090C-N-030 2.1-W100 200 3000 10.4 16.01) 49.5 2314 1902 30.8 19.5 19.3 29 691)
53.0 1.06 23
0.5
11
1.1 1.851)
093C-N-030 2.1-W100 186 2900 19.5 20.81) 34.0 2900 2653 34.0 17.6 34.0 33 371)
093C-N-030 2.1-W100 124 2900 19.5 20.81) 48.8 2784 2433 41.0 17.6 23.9 67 761)
42.0 3.6
42.0 3.6
1.1
1.1
11
11
1.9 2.081)
1.9 2.081)
22
22
Controllers with stabilized DC link circuit voltage (TVD) permit operation at higher speeds in certain cases.
The maximum torque Mmax must be limited to the maximum permissible torque of the mechanical structure by adjusting the
controller parameters during initial start-up.
1) Air-cooled motor
2) Limited to M due to controller continuous current rating
KB
Key to symbols used
OF
nmax
MdN
Mmax
-n100
-n90
M100-M90
MKB-DC-DC
JM
JB
mM
mB
MBr
PBM
PDC

Motor mass
Brake mass
Peak mains feedback power
DC link circuit continuous power rating
48
RE 82 701/02.99
Dimensions
NAM mains connection module
325
390
355
105
TVD power supply module
325
355
390
150
325
390
355
105
105
325
70
325
390
DDS 3 controller module
RE 82 701/02.99
49
355
390
DDS 2 controller module
355
TVM power supply module

Ordering Data
Part number 1130-211-20 DDS Digital Controller
Power section
Power supply
TVM
TVD
Feedback
for motor
MKD
MDD
Digital servo
feedback D
DDS2.1
Resolver feedback R
Stabilized
DC link circuit
voltage
Unstabilized
DC link circuit
voltage
DDS3.1
3.1-W030
3.1-W030
21
51
3.1-W050
3.1-W030
22
52
3.1-W050
3.1-W050
23
53
2.1-W100
3.1-W030
24
54
2.1-W100
3.1-W050
25
55
2.1-W100
2.1-W100
26
56
3.1-W030
3.1-W030
3.1-W030
31
61
3.1-W050
3.1-W030
3.1-W030
32
62
3.1-W050
3.1-W050
3.1-W030
33
63
3.1-W050
3.1-W050
3.1-W050
34
64
2.1-W100
3.1-W050
3.1-W030
35
65
2.1-W100
3.1-W050
3.1-W050
36
66
3.1-W030
3.1-W030
3.1-W030
3.1-W030
41
71
3.1-W050
3.1-W030
3.1-W030
3.1-W030
42
72
3.1-W050
3.1-W050
3.1-W030
3.1-W030
43
73
3.1-W050
3.1-W050
3.1-W050
3.1-W030
44
74
DDS... controller
Controller
for
10
2 axes
11
Configuration
(Interface modules with
connection accessories)
12
20
3 axes
21
30
4 axes
31
Axis 1
Axis 2
Axis 3
Axis 4
3.1-W050
3.1-W050
3.1-W050
3.1-W050
46
76
2.1-W100
3.1-W050
3.1-W050
3.1-W030
45
75
2.1-W100
2.1-W100
3.1-W050
3.1-W050
47
77
2.1-W100
2.1-W100
2.1-W100
2.1-W100
48
78
U1
Slot
U2
DAE
21
DAA
22
DLC
DEA
23
DSS
24
DAE
31
DAA
32
DLC
DEA
33
DSS
34
DAE
41
DAA
42
DLC
DEA
43
DSS
44
The power supply is designed for an average effective speed of up to 25% of the maximum rated speed.
Further configurations, combinations and options, e.g. external control desk, decade switch, displays
and customized programs, can also be supplied.
Motor and feedback cable to DDS
Motor assignment
MKD 025B-144
Part number,
Length in m
(max. 75 m)
Cable supply condition

Motor side
Controller side
with connector
without connector for
DDS2.1
DDS3.1
1130-001-17,
01
20
30
MKD 071B-097
1130-001-15,
02
21
31
MKD 090B-085
1130-001-40,
03
22
32
MDD 041B-N-100
MDD 065B-N-060
MDD 071A-N-060
1130-001-17,
04
23
33
MDD 071C-N-040
1130-001-15,
05
24
34
MDD 090C-N-030
1130-001-25,
06
25
35
MDD 093C-N-030
1130-001-40,
03
22
32
MKD 041B-144
50
RE 82 701/02.99
Indramat
English
E
11
21
11
21
15
25
16
26
11
21
11
21
15
25
16
26
11
21
11
21
15
25
16
26
CD-ROM1)
D
E
21
21
23
22
31
01
31
00
41
01
32
33
00
01
00
00
31
41
00
41
43
1)
with
Motion
with- manager for
without DDS2PC out DLC or CLM
Indramat
German
D
without
Documentation
Multi-axis
control module
without
80 Is
48 Os
Documentation
DDS controller
English
E
16 Is
16 Os
Control system
software
German
D
without
Controller
software
without
Multi-axis control module Control cabinet

(completely
CLM
wired)
01
42
The CD-ROM contains the documentation for both the controller and the multi-axis control module.
Ordering example
Ordering data
Explanation

Power supply module
= 10
Servo control system with DDS controllers

The TVM power supply module provides the DC voltage
for the DDS controllers
Power output section for operation of an MDD motor
with DDS 2.1 W100 controller or MDD motor with
DDS 3.1 W050 controller
DAE analog interface with incremental value output
CLM control module for two axes, with 16 inputs and
16 outputs
Completely wired control cabinet with operating controls
and displays
DDS2PC PC program for controller optimization
Motion Manager PC program for programming and
parametrizing the DLC or CLM
Documentation for DDS controller (German)
Documentation for CLM multi-axis control module
(German)
Power section
= 55
Configuration
= 21
Multi-axis control module = 21
RE 82 701/02.99
Control cabinet
= 21
Controller software
Control system software
= 01
= 01
DDS documentation
Multi-axis control
module documentation
= 11
= 11
51
Servomotors
Dimensions
MKD 25B-144-KG1
MKD 25B-144KG0
MKD 41B-144-KG1
MKD 41B-144-KG0
45
45
233
50j6
8
243
45
45
19k6
13
9.5
115
264
40
115
40
45
45
11
24k6
16
14

45
16
14
140
312
45
24k6
MKD 90B-085-KG1
11
MKD 90B-047-KG0
110j6
MKD 90B-047-KG1
110j6
45
95j6
19k6
95j6
264
45
13
9.5
MKD 71B-097-KG1
MKD 71B-061-KG0
312
140
50
50
MKD 71B - 061- KG 1
MKD 112
45
Servomotors
1 With holding brake
2 Without holding brake
Cylindrical drive shaft
Resolverfeedback Multiturn
Winding code
45
21
32k6
Overall motor length

Motor frame size
14
130j6
82
30
MKD 71B-061-KG1
18
60
95
56
20
45
6.6
4.5
45
2.5
14k6
63
9 k6
40 j6
2.5
MKD 112 B = 375

MKD 112 C = 440
MKD 112 D = 505
Digital servomotor
1921
52
RE 82 701/02.99
MDD 71A-N-060-N2S-095 GB1


45
208
95j6
19k6
10
288
40
40
MDD 90C-N-030-N2L-110 GA2

45
45
405
11
24k6
110j6
16
16
140
50
RE 82 701/02.99
10
115
53
45
13
19k6
13
45
45
95j6
MDD 71C-N-040-N2S-095 GB1
115
Frequency Inverter VF1000S SMART DRIVE

Product Overview
These compact VF1000S series frequency inverters offer a cost-effective
and convenient means of controlling three-phase asynchronous motors.
The power spectrum ranges up to 750 W for 4-pole motors. Velocity can
be preselected by inputting three fixed frequencies or an analog command
value.
Users have a choice of several different options:
From an unwired 2-quadrant frequency inverter through to a
completely wired 4-quadrant frequency inverter controlled by PLC.
These frequency inverters are mainly employed for tasks involving
transporting and positioning with relatively few stations, as well
as simple machining or processing operations, such as cutting,
sawing, or applying adhesives.
Single or three-phase
connection
H1
H2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Small, compact devices
Mannesmann Dematic
Braking chopper
54
RE 82 701/02.99
Easy, reliable operation
Multifunctional KEYPAD
operating controls
Hz
sto
re p
tur
n
sta
e nr t
te
Basic device with heat sink
Basic device with operating

control unit
Memory card
RE 82 701/02.99
Rapid adaptation via

chipcard
55

Operation and Menu Structure
KEYPAD Operating Controls
The multifunctional KEYPAD helps you
keep your drive under control simply
and easily.
The KEYPAD is detachable and can thus be

used to control other frequency inverters in
the VF1000 series.
LCD display
140 segments, green/red backlit
Down cursor key
Return within menu structure
Hz
sto
re p
tu
1
rn
sta
e nr t
te
Up cursor key
Continue within menu structure
Start/Enter key
Start (CTRL menu), acknowledge message,

or select menu
Stop/Return key
Stop (CTRL menu), cancel, or exit selected

menu
SMARTCARD
Chipcard data memory, for storage of

device settings
Connection cable
Length max. 0.35 m
SMARTCARD memory card
Main menus
3
5
6
The SMARTCARD serves to store all parameters for data backup and data transmission. Your frequency inverter can be
adapted to your application in a matter of
seconds. Simply slot the SMARTCARD into
the KEYPAD and press the appropriate keys
to read data from or save it to the SMARTCARD.
VAL menu: displays actual values

VAL
PARA menu: changes parameters
CTRL: controls motor via KEYPAD
CARD menu: loads/stores device

settings (GE) with the SMARTCARD (SC)
56
PARA
CTRL
CARD
RE 82 701/02.99
VAL menu (actual

values) selected
PARA menu
(parameters) selected
VAL
start
enter
VAL
Display actual values
PARA
Continue with Start/Enter
start
enter
PARA
Select parameter,
e.g., FMIN1
Hz
Hz
start
enter
Change parameter setting

in off-line mode (inverter
stop)
VAL
Next actual value

parameter
stop
return
Hz
start
enter
Establish new actual value
start
enter
Read parameter setting

in on-line mode (inverter
start)
VAL
PARA
Hz
stop
return
stop
return
CTRL menu (control

motor using KEYPAD)
selected
PARA
Load/store menu
for device setting
(GE) using the
SMARTCARD (SC)
CTRL
CARD
start
enter
READ = load GE from SC

WRITE = save GE to SC
LOCK = write protect SC
UNLCK = cancel write
protect
CTRL
Enter password
Factory setting = 573
start
enter
CARD
start
enter
CTRL
Set frequency value

(KEYPAD), e.g. 10 Hz
Hz
stop
return
Start/Enter for activation

of motor-operated
potentiometer function
(MOP)
start
enter
CARD
Start selected function

using Start/Enter key
start
enter
stop
return
MOP function
CARD
Function completed
without error
stop
return
RE 82 701/02.99
start
enter
57

Technical Data and Dimension Drawings
Motor-side output
VF1202S
S1)
(W)
(VA)
(V)
375
IN1)
1.1 x IN1)
1.5 x IN1)
Frequency resolution
(A)
(A)
( Hz)
(%)
0 to 400
0.1 of Fmax (0.05 Hz min.)
(A)
840
230 V
400/460 V
230 V
400/460 V
1.9
2.1
2.9
3.2
3.5
4.8
1.9/1.7
2.1/1.9
2.9
3x0 to 230
VF1204S
1400
750
VF1402S
1450 3x0 to 400/460
Mains-side input
Mains voltage
Asymmetrical
mains voltage
1) 2)
PV2)
(V)
(%)
(Hz)
(A) T
(%)
(W)
1 x 10
96
25
1 x 230 +15/-20%
1 x 10
95
35
3 x 10
94
45
VF1202S
VF1204S
48 to 62
3 x 400 -15%
3 x 460 +10%
VF1402S
TN
rF
PT
PH
TL
TT
(%)
(%/C)
(%/m)
(C)
(C)
Cooling
type
(C)
15 to 85,
VF1202S
non
VF1204S
0 to 40 Convection
VF1402S
dewing
2)
40 to 50 C
(VDE0160)
referred to output section switching

frequency of 8 kHz
at rated voltage and rated current
Protection
Mounting
5 per 1000 m
2,5
over
-25 to +55 -25 to +70
2g
for range
Key to symbols used

1)
Permissible
vibration
IP20,
vertical
VBG4,
1000 m above s.l.:
(VDE0160)
(VDE0160)
(IEC 68-2-6)
NEMA1
wall mounting
max. 2000 m above s.l.
P
S
U
IN
1.1 x IN
1.5 x IN
f
I
PV
TN
F
rF
PT
PH
TL
TT
Recommended power rating with 4-pole standard motor

Device power rating referred to mains voltage
Voltage
Phase current
Continuous current load
Overload factor for 60 s
Rotating field frequency
Recommended mains protection
Efficiency
Power loss
Cooling air temperature (1,000 m above sea level)
Frequency
Relative humidity
Power loss as a function of cooling air temperature
Power loss as a function of mounting altitude
Storage temperature
Transport temperature
58
RE 82 701/02.99
Dimensions
Basic device
133
4.8
170
183
65
32.5 32.5
20
Device with heat sink

67.5
196.5
133
K1
4.8
206.5
65
Operating controls
62
21
158
Hz
RE 82 701/02.99
stop
return
start
enter
59

Performance Data and Dimensions for BC1300/1400 and Mains Filter
Braking Chopper BC 1300/1400 for VF1000S
Technical Data
Braking
chopper
BC1300
BC1400
Inverter
VF1202S
VF1204S
Peff Peff Peff Peff Peff

100% 50% 25% 12% 6%
DC DC DC DC DC
(W)
(W)
(W)
(W)
(W)
90
140
210
310
450
Pp
Pred
IBr
Uon
Uoff
Type of
braking
resistor
0.7
VF1402S
4.0
2.7
390
750
381
Heating
1.5
cartridge
740
Thermostat
switch
contact
(mm2)
(kW) (kW) (A) DC(V) DC (V) DC
1.5
Term. 9/10
DC link circ.
connection
maximum
length 0.5 m
250 V ~ 10 A
Environmental Conditions
Braking
chopper
BC1300
BC1400
Protection
IP10
(in installed condition)
H above s.l.
rF
(C)
(m)
(%)
0 to 40
1000 max.
15 to 85,
non dewing
Permissible
vibration
Mounting
2g
(IEC 68-2-6)
vertical
wall mounting
Dimensions
Braking chopper BC1300/1400
65
32.5 32.5
120
4.8
1
2
3
4
5
6
7
8
9
10
11
170
183
H1
H2
20
Key to symbols used
Peff
Pp
Pred
IBr
Uon
Uoff
A
T
H
rF
Braking power
Peak braking power
Automatic power reduction (after 6 s)
Brake current
Start-up current
Cut-out current
Connecting conductor area
Cooling air temperature
Mounting altitude above sea level
Relative humidity
60
RE 82 701/02.99
Mains Filter
Technical Data
Inverter
Type
VF1202S
NFE6.1
VF1204S
NFE6.0
VF1402S
NFD4.1
Limit
curve
Rated
current
(A)
Rated
voltage
(V)
Working
current
(mA)
1x230V AC + 10 %
Overload
Connections
0.21
1.5
Class B
4
3x400V AC + 10 %
Flat connector
A6.3 x 0.8
1.5 x IN for
1 minute
per hour
Input: term. 1.5 mm2

Output: stranded wire
1.3
Dimensions
Mains filter NFE6.0, NFE6.1
Mains filter NFD4.1

a
d
e
Type
NFE6.0
159
44.5
143
50.8
4.7
NFE6.1
88.4
40
75
52
5.3
NFD4.1
145
40
135
75
55
7 x 5.3
300
RE 82 701/02.99
61

Ordering Code
Part
number
Model version
Mains filter
Heat sink
Operating
controls
without with without with without with
1130-390-00
VF1202S
01
VF1204S
02
VF1402S
03
Memory
card
02
00
01
00
01
Braking
chopper
without with
01
00
Drive signals
00
01
03
without with
Analog signal
and 2 digital
inputs
01
01
00
02
Ordering example
Ordering data
Explanation
Frequency inverter
Model version
= 01
Type VF1202S
Mains filter
= 01
With external mains filter, single-phase

1 x 230 V AC
Heat sink
= 00
Without
Operating controls
= 01
With multifunctional operating control unit

and chipcard drive
Memory card
= 01
With chipcard
Drive signals
= 01
Analog signal and two digital inputs
Braking chopper
= 00
Without
Completely wired frequency inverter with PLC control option and

customized operating control unit on request.
62
RE 82 701/02.99
Three-Phase Motors
Data and Dimensions
Three-Phase Motors from Mannesmann Dematic with Spur Gearing
Technical Data
Motor type
Rated power
Rated speed
Rated torque
P in [kW]
n in [min-1]
MN in [Nm]
Spur gearing
Reduction
ratio
Output
speed
Output
torque
nout in [min-1]
Mout in [Nm]
Z.A63B4
0.18
1380
1.2
DFV10DD
2.94 - 66.5
20 - 459
4 - 84
Z.A71A4
0.25
1390
1.7
DFV10DD
2.94 - 44.8
20 - 445
5 - 82
Z.A71B4
0.37
1380
2.5
DFV10DD
DFV20DD
2.94 - 32.0
10.4 - 55.0
42 - 445
20 - 129
8 - 84
27 - 145
Z.A80A4
0.55
1410
3.7
DFV10DD
DFV20DD
2.94 - 23.3
5.45 - 40.2
61 - 479
35 - 259
11 - 87
20 - 150
Z.A80B4
0.75
1410
5.1
DFV10DD
DFV20DD
2.94 - 16.3
4.41 - 29.1
87 - 479
48 - 319
15 - 82
22 - 148
DFV 10 DD
k
175
39.5
3 16
g1
z3
108
95 j6
20 k6
108
h1
40
10.5
y3
136
82
21.6
6P9 DIN 6885-A6x6x32
115
s3
14
DIN332-DR M6
Motor
ZNA63/71 without brake
ZBA63/71 with brake
ZNA80/90A without brake
ZBA80/90A with brake
450
525
489
581
275
350
314
406
g1
h1
s3
y3
z3
140
124
162
PG 13.5
51
157
157
134
162
PG 16
51
170
DFV 20 DD
k
8P9 DIN 6885-A8x7x40
213
123
g1
26.6
z3
15 17
h1
y3
97
158
110 j6
s3
11
130
50
123
25 k6
16
DIN332-DR M10
Motor
ZNA63/71 without brake
ZBA63/71 with brake
ZNA80/90A without brake
ZBA80/90A with brake
RE 82 701/02.99
488
563
527
619
275
350
314
406
g1
h1
s3
y3
z3
140
124
182
PG 13.5
51
157
157
134
182
PG 16
51
170
63
Gear Motors with Integrated Frequency Inverters

Product Overview
Frequency inverters have been very much refined in recent years. The latest
step in this development process has been to incorporate them directly in
three-phase motors.
Motor types:
Z.I 71 A4
Z.I 71 B4
Z.I 80 A4
Z.I 80 B4
Z.I 90 A4
This offers several different advantages:

Reduced installation effort
Shielded motor cables and filters are no longer required.
Easy start-up
Since the motor and the frequency inverter have already been optimally paired
and adapted, the number of parameters reduces to plant-specific settings only.
Cost advantage due to smaller-size control cabinet
Easy integration into master control systems via Interbus, Profibus-DP,
MDC-AT-Bus, digital switching signals and analog command values
64
RE 82 701/02.99
Variable-speed Gear Motors from Mannesmann Dematic

Technical Data
Power supply
e.g., Interbus
Profibus-DP
MDC-AT-Bus
Mains
voltage
Mains
frequency
Motor
power rating
Braking
chopper
Braking
resistor
Motor
contactor
Protection
Ambient
temperature
380 - 500 V +/- 10%
50/60 Hz
up to 1.9 kW
integrated
integrated
(for move
commands)
integrated
IP54
0 to 40 C
Size
Type
g1
m1
y3
71
207
225
61
77.5
14
30
80 + 90 A
214
225
61
77.5
24
50
ZNI
ZBI
ZNI
ZBI
Ordering code in preparation!
m1
g1
y3
d
RE 82 701/02.99
65
Stepping Motor Power Output Stage Modules WD3-004 / WDM3-004

Product Overview
Stepping motor power output module for 3-phase stepping motors,
for wall mounting.
WD3-004 for one 3-phase stepping motor
WDM3-004 for two 3-phase stepping motors

L
N
PE
Failsafe operation
DE
01
RO
MOT.
N
03
SIG
N
ROT.ERR.
CO
READY
00
EN
X1
SIG
04
Visual status display

06
EP
I-R
GAED
T/E
NA
05
PH
.CU
RR
RE
AD
Y
FA
UL
08
T
TE
MP
09
OV
ER
09
-VO
LO
W-V LT
OL
T
07
NA
AL
X2
SIG
ST
NA
IT.
ST
EP
- I- GRED
AT
/EN
PH
.CU
ST
EP
- I- GRED
AT
/EN
PH
.CU
RR
RR
X1
X2
FAULT
U
V
W
11
U
V
W
U
V
W
TEMP
OVER-V
LOW-V
RE
AD
X1
X2
X2
X2
WD3-004
66
RE 82 701/02.99
Easy mounting
L
N
PE
Silent, economical and powerful
WDM3-004
RE 82 701/02.99
67

Advantages/Functions
Economical
Mounting
Simple attachment by means of two
screwholes in the mounting plate.
The unit can be fastened to the
mounting plate either by the rear
panel or the left side panel.
Precise
Power supply
The power output stage runs on 230 V AC
mains voltage (switchable to 115 V AC).
Step monitoring
(optional / for WD3-004 only)
A pulse generator is used to transmit signals for correct or incorrect execution of
positioning to the external control system.
Control signals
All input signals are metallically isolated
from the power output stage via optocouplers. Depending on the unit type, the
signal input levels will be 24 V or 5 V.
Processable control signals:
- Pulse
- Direction
- Gate / enable
- Current mode
- Micro-step
Current setting
Easy and precise setting using rotary
coding switches.
Step number setting

Easy setting of the motor step number
for standard or micro-step operation.
Visual display
LEDs for:
- Ready
- Overtemperature
- Power supply under-/overvoltage
- Short-circuit between motor phases
68
RE 82 701/02.99
Function diagram WD3-004
L1
230 V AC mains
Power supply
WD3-004
External
control system
Power output
stage
Motor
Function diagram WDM3-004
L1
230 V AC mains
Power supply
WDM3-004
Power output
stage
Motor 1 Motor 2
RE 82 701/02.99
69
External
control system

Data and Dimensions
Mains-side Input
230
WD3-004
WDM3-004
115
230
115
Imax
Ion
PV
(V)
(Hz)
(A)
(A)
(A)
(W)
-20%, +15%
50 to 60
-20%, +15%
50 to 60
5.5
max. 70
10
6
max. 70
10
6
10
6
10
45
60
Motor-side Output
IP
UM
(A)
(V)
0.6 to 2.5
325
WD3-004
WDM3-004
Input Signals
Signal inputs: pulse, direction, gate, current mode,
micro-step optodecoupled, polarity-reversal protected.
fS
Step number
standard
micro-step
(kHz)
WD3-004
WDM3-004
max. 200
200,
2000,
400,
4000,
500,
5000,
1000
10 000
Ulow
Input
current
Input
resistance
(V)
(mA)
()
20 to 30
<3
10 to 25
2000
2.5 to 5.25*
< 0.4
7 to 25
150
Signal
level
Signal voltage
Uhigh
(V)
(V)
24
*) Pulse signal voltage 3.5 V to 5.25 V from stepping rate 50 kHz to 200 kHz at pulse-to-pause ratio 1:1
Environmental Conditions
WD3-004
WDM3-004
Key to symbols used
tst
(kg)
(C)
(C)
0 to 50
-25 to +70
Protection
Cooling
type
Mounting
IP20
convection
3.2
vertical
wall mounting
3.4
U
UM
f
fs
Imax
Ion
Mains voltage
Motor voltage
Mains frequency
Stepping rate
Current consumption
Start-up current
70
I
IP
PV
t
tst
m
Recommended mains protection

Phase current
Power loss
Ambient temperature
Storage temperature
Mass
RE 82 701/02.99
WD3-004
5.5
187
25.5
248.5
12
279.5
19
240
52
WDM3-004
5.5
187
25.5
12
28
248.5
279.5
19
52
240
Mains filter FF 343
L1 N1 PE
100 85 70
L N PE
50
110
70
RE 82 701/02.99
71
TURBO-STEP PC Controller Boards and Controller Module CNC 45 S

The quick and easy way to a complete system:
Installing a 1 to 8-axis stepping motor controller board
in your PC.
Provides unlimited possibilities for CNC applications.
Programming with machine commands to DIN 66025,
or integration into motion sequence routines written
in high-level or machine language.
Applications:
Machining
Measurement
Material transport
Up to 8 axes per PC controller board

Up to 4 axes per controller module
Effortless programming of
motion sequences via PC
Turbo-Step
System box
All I/Os provided with optocouplers for

guaranteed protection of the PC
72
RE 82 701/02.99
Motion sequencing by PC
or controller module
Easily mounted using system box
I
0
mA
315
5S
C4
CN
mo
Wall-mounting
system box
I/O
4V
+2
CNC 45 S
Inexpensive and powerful

Maximum economy,
even with single units
RE 82 701/02.99
73

Description
Technical Data
System components
Input signals
TURBO-STEP 45 S controller module,

system box, driver, CNC program,
hardware test program.
End positions, E-STOP, free input bits,

max. level 24 V, presettable to high or
low active.
Installation and connection
CNC program to DIN 66025
For installation in an ISA slot, wiring of

motors, switches and signals via system
box.
Command editor and sequential program

with perfect syntax test and help system.
Clear presentation on color monitor,
exceptionally user-friendly handling.
Output signals
Step and direction for each axis, min. level
5 V, as well as 1.5 A Darlington driver with
protective diodes for free output bits (relays
or solenoid valves).
Driver
Libraries for C++ and TurboPascal, as well
as DLL file for Windows applications.
Move commands in the numerical range

-32768 to +32767:
TURBO-STEP 45 S
Linear interpolation X, Y
up to max.
50 kHz
Linear interpolation X, Y, Z
up to max.
50 kHz
Linear interpolation X, Y, U
up to max.
50 kHz
Circular interpolation X, Y
up to max.
50 kHz
Circular interpolation X, Y
with tangential control in U
up to max.
25 kHz
Elliptical interpolation X, Y
up to max.
25 kHz
Elliptical interpolation X, Y
with tangential control in U
up to max.
25 kHz
Independent move commands X, Y, Z, U
up to max.
25 kHz
Spline interpolation X, Y, Z, U
up to max.
25 kHz
Move commands in the numerical range

-1.07109 to +1.07109 :
74
RE 82 701/02.99
Function
TURBO-STEP 45 S
System concept with effective
multitasking
The TURBO-STEP 45 S controller is equipped
with an integral processor, memory, timer
and pulse shaper to generate and output
motor signals directly from the PC without
taking up any of the PC's internal computing
resources. This permits extremely precise
controlling of step pulse timing.
While this being done, the PC runs the CNC
program or a program written by the user.
The program sends commands consisting
of only a few bytes to the controller. These
commands set the ramps and the velocity
and initiate axis movements. While the
controller is executing a move command,
the PC program has plenty of time to
process the next command, perform other
calculations or control a user-specific chart
or diagram. The PC also has sufficient time
available to provide ergonomically optimum
visualization of data on the monitor.
The controller encompasses virtually all
useful and desirable functions, e.g. continuous curves made up of arcs and linear
segments with a common start and stop
ramp, tangential control for a rotary axis,
2 to 4-axis reference point interpolation,
and many more.
The Turbo-Step 85 S stepping motor controller is available for 8-axis applications.
More information on this product can be
obtained on request.
The stepping motor power output stage
module WD3-004 and the digital DKC
controller can be readily connected to
the controller module.
RE 82 701/02.99
PC
Turbo-Step
stepping motor
controller with
integral
optocouplers
PC controller
Program to
DIN 66025
4 to 6 outputs
System box
3 to 4 inputs
Control signals
75
Power output
stage
1
Power output
stage
4 (8)
Motor 1
Motor 4 (8)
e.g. WD3-004
or
DKC 1.1

Function and Dimensions
Function
Module
CNC 45 S
Economical concept for fixed
programmed sequences
Turbo-Step
stepping motor
controller with
integral
optocouplers
The command set and the function principle of the controller are identical to those
of the TURBO-STEP 45 S. The CNC 45 S
is a stand-alone device which manages
without an expensive PC.
A PC is, however, required to write the
program for storage on the controller
module's PC board. The completed CNC
program is compiled and stored in an
EPROM. This EPROM is then mounted
on the controller module's PC board.
Once the PC board has been reinstalled
in the controller module, the plant is
ready to operate.
EPROM with program
4 to 6 outputs
System box
3 to 4 inputs
Control signals
System Box
This connection box simplifies wiring of
the controller, the output stages, limit
switches, and other peripherals. All connections are made via screw terminals,
thus eliminating the need for soldering.
76
Power output
stage
1
Power output
stage
4
Motor 1
Motor 4
RE 82 701/02.99
Dimensions
Controller Module CNC 45 S
System Box
160
44
237
System Box, wall mounting version

44
RE 82 701/02.99
77
255
230
8.5
160
238
308
44
238
341

Product Overview
STAR step stepping motor controls for 1 to 4 axes
with power controller for 3-phase stepping motors
with integral PLC.
Application possibilities:
Handling systems
Positioning and feed tasks
Dispensing/dosing machines
Palletizing, etc.
Ready for connection to 230 V AC
Clearly structured keyboard and display

for immediate data recognition and ease of operation
78
RE 82 701/02.99
Powerful and economical

Simultaneous axis positioning and control
of complex machine motion sequences
Self-monitoring ensures
high operational reliability
Plug connections
simplify installation
STAR step
Fixed or mobile due to

installation either in 19"
rack or in table-top housing
RE 82 701/02.99
79

Technical Data
Hardware
Software
Mechanical design
Step monitoring (optional)
Programming
STAR step position controls are available

in two versions:
A pulse generator in the motor signals

successful or unsuccessful completion of
positioning to the control system.
This may be done in two different ways:
- 19"rack (for installation in control

cabinet)
- Table-top housing, 3 (6) modules
high
Electrical connections
Plug-in connections at the rear:
-
230 V AC mains input

motor power supply
reference and limit switches
inputs/outputs
Serial interface
RS 232:
- for UP/DOWNLOAD of programs
- for command transmission from
a PC to the control system
RS 485 (optional):
- proprietary field bus system for
control of a decentralized I/O
module, control and operating
elements, or power sections
Operator interface
The control panel comprises:
- 4x20-character clear text display
- 35 keys
These allow:
- changing of machine parameters
- display of machine statuses
- programming in the MCstep
programming language
External control panel (optional)

- hand-held terminal with 4x20character LCD display
- 20 membrane keys
- electric handwheel and E-STOP
button for remote control of the
system
- via the keyboard using MCstep, a

simplified programming language
with limited scope
- via a PC in PLC language
(MC 1, optional)
Program and memory capacity

MC 1:
Solution of complex tasks
- multitasking (4 parallel PLC
programs)
- macrotechnology possible
- symbolic programming
- up to 16,000 PLC commands
- program memory for storage of
up to 28,000 variables
- 32 timers from 0.01 to 0.1 s
MC Step:
- 11 user-defined commands
- program memory with 1200 lines
- number of programs determined by
settable program length (e.g., program length 400 lines = 3 programs)
Remote maintenance (on request)

PLC functions
The following are provided:
Remote maintenance including diagnostics

and fault clearance can be performed via a
modem connected to the control system.
- 16 short-circuit-proof, positive action

outputs (24 V DC / 1 A)
- 24 optodecoupled inputs
(24 V DC / 10 mA)
Safety devices
Safety functions
- interrogation of hard (mechanical)
limit switches
- soft limit switches
- short-circuit-proof PLC outputs
- operating voltage monitoring for
power sections
- temperature monitoring for power
sections
These I/Os are used to control/monitor:

- pneumatic valves
- relays and contactors
- limit switches
I/O expansion (optional)

E-STOP circuit (optional)
choice of:
This option comprises a contactor to cut off

the voltage supply to the power output
stages, without cutting off the PLC voltage.
- 24 digital inputs (24 V DC / 10 mA)

- 16 digital outputs (24 V DC / 1 A)
or:
- 4 analog inputs (0-10 V DC / 5 k)
- 2 analog outputs (0-10 V DC / 20 mA)
80
RE 82 701/02.99
Function diagram
L1
230 V AC
N
STAR step
Keyboard
+
display
Transformer
RS 232 (RS 485)
Power supply
unit
24 V DC
Positioning and
PLC controls
up to 192 inputs
up to 128 outputs
325 V DC
Dimensions
Motor
Power output
stage
Motor
Power output
stage
Control signals
STAR step, 3 modules high

340
132.5
426.72
STAR step, 6 modules high

426.72
265
The STAR step 6-module size is required

for versions with more than 3 encoders.
RE 82 701/02.99
81
340

Programming
MC step
programming commands
Additional functions:
ABS
Absolute positioning
REL
Relative positioning
REF
Reference cycle
F>>
Feedrate
TIM
Queuing
CNT
Counter
INP
Set inputs
OUT
Set outputs
LBL
Define flag
JMP
Conditional or unconditional jump to line, flag or program
SUB
Conditional or unconditional subroutine jump to line, flag

or program
Linear interpolation
On-line mode
If a program line contains two absolute

positioning commands one after the other,
these two axes will be operated in linear
interpolation mode.
In the as-delivered condition, the control

system contains a single-command program permitting on-line command processing via PC. (Drivers for C++, Delphi
and Visual Basic are available for PC
programming of this function.)
Waiting for entry

1. from keyboard
A flag can be set to halt the automatic
program at a certain point. The display will
show the next line in the program. Up to
four commands can be edited in this program line. These new commands will be
executed when the ENTER key is pressed.
2. from PC
A flag can be set to halt the automatic
program at a certain point to wait for data
transmission via the RS 232 interface.
Once the data has been transmitted it will
be processed immediately and the automatic program subsequently resumed. (Drivers
for C++, Delphi and Visual Basic are available for PC programming of this function.)
(Software optional.)
82
External START/STOP
When this function is activated, the
program sequence can be started or
stopped in automatic mode via two
external switches.
BCD inputs
In the automatic mode, one of 32 programs can be selected via a BCD switch.
RE 82 701/02.99
Programming Example:
Handling application for a two-axis
pick-and-place system
Task:
On completion of the homing cycle and on
receipt of a start signal, the axes are to
move to position A (0/-1000). At this position, an object (e.g. a cardboard box) is
to be picked up by a gripper. The axes lift
the object over and around an obstacle to
position B (1500/-1000) and place it there.

This pick-and-place cycle is repeated 10
times. The system then returns to home
position (0/0) and waits for a new start
signal.
(0/0
)
X
Programming:
Line
Command
01
02
03
REF
REF
LBL
INP
CNT
ABS
OUT
TIM
ABS
ABS
ABS
OUT
TIM
ABS
ABS
CNT
JMP
JMP
04
05
06
07
08
09
10
11
Command
option
Y
X
=1?
1 SET
Y
SET
Y
X
Y
RES
Y
X
1 DEC
1 LBL
LIN
Command
data
Comment
Homing cycle of axis Y
Homing cycle of axis X
Programming jump flag 2
Interrogate input 1 (start signal) for high level
Set counter 1 to 10
Absolute positioning of axis Y to -1000
Set output 1 (gripper)
Wait 1 second
Absolute positioning of axis Y to 0
Absolute positioning of axis X to 1500
Absolute positioning of axis Y to -1000
Reset output 1 (gripper)
Wait 1 second
Absolute positioning of axis Y to 0
Absolute positioning of axis X to 0
Reduce counter 1 by 1
Conditional jump to flag 2 if counter 1 is at 0
Unconditional jump to line 4
2
1
10
-1000
1
1.0
0
1500
-1000
1
1.0
0
0
1
2
4
Note: Any line can contain up to 4 commands

RE 82 701/02.99
83

Ordering Data and Dimensions
Type
designation
Axes
Part number
STAR step
STAR step
Hand
engineering
mannesmann
Rexroth
Auto
RS232
Deutsche Star
1131-212-00
Type
designation
Rotation monitoring
Version
Option Output stage
Holding brake
Option
Number
Option
Number
01
D901
01
1 encoder
01
1 brake
02
D902
02
2 encoders
02
2 brakes
03
D901 + D902
03
3 encoders
03
3 brakes
04
2 x D902
04
4 encoders
04
4 brakes
Axes
Part number
Mains filter
without
Version
with
Option
Output stage
D901
01
24 V signals
D901
02
WD3-004
WDM3-004
00
Rotation monitoring
5 V signals
Option
Number
00
without
01
1 encoder
00
without
01
1131-212-10
D902
03
24 V signals
D902
04
System box 1 with 5 V output level

(for WD3-004 or WDM3-004)
Type
designation
System box 2 with 24 V output level

(for DKC)
Part number
TURBO-STEP
5 V signals
Axes
1131-211-80
CNC 45 S
1131-211-90
84
Version
Option
Description
03
TURBO-STEP 45 S
05
TURBO-STEP 45 S
with system box 1
06
TURBO-STEP 45 S
with system box 2
04
TURBO-STEP 85 S
01
Controller Module
and system box 1
02
Controller Module
and system box 2
RE 82 701/02.99
Housing
E-STOP circuit
I/O expansion
Interface
Option
Version
Option
Description
Option
Inputs/Outputs
Option
Description
01
19" rack
00
without
01
24 (I) / 16 (O) digital
01
with RS 232
01
with E-STOP
02
4 (I) / 2 (O) analog
02
02
table-top
housing
with RS 232
and RS 485
Cable set
comprising:
Part number
Length in m
(max. 50 m)
Motor cable
1130-801-30
10
20
10
20
Motor and
brake cable
1130-801-31
11
21
11
21
Motor and
encoder cable
1130-801-32
22
12
22
Motor, brake
and encoder cable
1130-801-33
23
13
23
Cable supply condition motor side

Terminal box
With connector
(standard motor)
Cable supply condition control side

STAR step
WD3-004
WDM3-004
Ordering example
Ordering data
Explanation
STAR step stepping motor controls

Version
= 02
Rotation monitoring
= 00
Holding brake
= 01
Housing
= 01
E-STOP circuit
= 01
I/O expansion
= 02
Interface
= 01
RE 82 701/02.99
Part number: 1131-212-00

Power output stage D902
Without rotation monitoring
For control of a holding brake
Completely wired in 19" rack
With E-STOP circuit
With an additional 4 analog inputs and 2 analog outputs
With RS 232 interface
85

Torque/Speed Diagrams and Dimensions
Power output sections
WD3-004 and WDM3-004
Motor
VRDM 368 / 50 LWB
M (Ncm)
160
120
80
40
0
6
3 4 5 6 7 89100
3 4 5 6 7 891000
3 4000
n (min-1)

WD3-004 and WDM3-004: 1.8 A / 325 V
Motor
VRDM 397 / 50 LWB
M (Nm)
2
1,5
1
0,5
0
6

WD3-004 and WDM3-004: 2 A / 325 V
Motor
VRDM 3910 / 50 LWB
10
3 4 5 6 78 9100
3 4 5 6 7 891000
3 4000
n (min-1)
M (Nm)
4
3
2
1
0
6
3 4 5 6 7 89100
3 4 5 6 7 8 9 1000
3 4000
n (min-1)

WD3-004 and WDM3-004: 2.3 A / 325 V
Motor
VRDM 3913 / 50 LWB
M (Nm)
6
4.5
3.0
General note:
These charts were plotted
with the stepping motors set
to 1000 steps/revolution.
1.5
0.0
10
3 4 5 6 7 89100
3 4 5 6 7 891000
3 4000
n (min-1)
86
RE 82 701/02.99
Dimensions
3-phase stepping motors
VRDM 368/50 LWB
VRDM 397/50 LWB

VRDM 3910/50 LWB
30
85
70
6.5
70
85
1160.5
60 h8
21-0.5
57.2
47.14
5.2
47.14
57.2
8 -0.013
38.1 0.025
VRDM 3913/50 LWB

1.6
2
5
22.6
10
Type
VRDM 397 110

VRDM 3910 140
VRDM 3913 170
d h6
12
12
14
Data
3-phase stepping motors
Motor
VRDM 368
50 LWB
VRDM 397
50 LWB
Stepping number
Step angle
Maximum
torque
Mass moment
of inertia
Holding torque
Mass
VRDM 3910/
50 LWB
200 / 400 / 500 / 1000

()
1.8 / 0.9 / 0.72 / 0.36
(Nm)
1.5
2.0
4.0
(kgcm2)
0.38
1.1
2.2
3.3
(Nm)
1.74
2.26
4.52
6.78
(kg)
1.1
2.05
3.1
4.2
The 3-phase stepping motors are available with plug connectors and optionally with encoder and brake.
RE 82 701/02.99
VRDM 3913/
50 LWB
87
Motor Selection
Calculation Principles
For systems with
toothed belt drive:
Values for
acceleration time
acceleration distance
acceleration
velocity
can be found in the respective linear motion system catalog.
For systems with

ball screw drive:
Servomotor acceleration
characteristics
Note:
The following calculation principles are for
provisional dimensioning of linear motion
systems only.
Horizontal installation:
(1) MB = 0.8 Mmax MR
Mmax Mperm
Vertical installation:
(2) MB = 0.8 Mmax MR MG
Mmax Mperm
Moment due to weight

(vertical installation)
Condition: S MG < Mbrake
S : safety factor
recommended value S 2
(3) MG =
1.561 10-3
mlin P
i
Fixed base plate, moving carriage:

mlin = mb + mfr
Fixed carriage, moving base plate:
mlin = mtot mb
Mass moment of inertia of system

with additional load
See table in the appropriate linear motion
system catalog
For handling:
6 JM > Jfr
MB
= Maximum motor
accelerating torque
Mmax = Maximum motor
torque
MR = Friction moment
MG = Moment due to weight
Mperm = Maximum permissible
drive torque
P = Screw lead
i = Transmission ratio
mlin = Total moved mass
(Nm)
(Nm)
(Nm)
(Nm)
(mm)
(kg)
mb = Moved mass
(carriage)
mfr = Additional load
(kg)
(kg)
mtot = Total mass (incl.

linear motion system)
(kg)
mlin = Total moved mass
(kg)
Jfr
For machining:
1.5 JM > Jfr
(Nm)
JM
= Mass moment of
inertia of
additional load
= Mass moment of
inertia of motor
(kgm2)
(kgm2)
(4) JS = from linear motion system catalog
88
RE 82 701/02.99
Mass moment of inertia

JS : from linear motion
system catalog
J
Jfr : Jfr = 2S + JK
i
(5)
JG=
JS
Speed
v : see linear motion system catalog
(6)
+ JM + JK + JRV
i2
i v
n1 =
1000
n1 nMmax
Acceleration time
JG : from equation (5)
MB : from equation (1) or (2)
n1 0.10472
(7) th = JG
(8)
a=
(9)
sh = 0.5 a th2
MB
Acceleration
JG = Total reduced mass

moment of inertia
JS = Mass moment of
inertia of system
with additional load
JM = Mass moment of
inertia of motor
JK = Mass moment of
inertia of coupling
(motor side)
JRV = Mass moment of
inertia of timing
belt side drive
(kgm2)
(kgm2)
(kgm2)
(kgm2)
(kgm2)
v
= Maximum velocity
n1
= Speed, motor side
nMmax = Maximum motor
speed
(m/min)
(1/min)
th
= Acceleration time
(s)
= Acceleration
(m/s2)
sh
= Acceleration distance
(m)
(1/min)
th 60
Acceleration distance
RE 82 701/02.99
89
Motor Selection
Calculation Example
Ball Rail Table
TKK 30-325 Al
LT = 320 mm
2% preload
with bellows
with MDD 71C-N-040 motor
(motor attachment and coupling,
without gear)
Starting data
A mass of 150 kg is to be moved 500 mm
within a maximum of 1.0 s (total time). The
axis is installed horizontally.
Note
Selection of the ball screw drive

Taken from the Aluminum Ball Rail
Tables catalog.
500
F=0N
m=150 kg
This calculation example is of a representative nature only. Calculations for other

linear motion systems are performed analogously. The related values and charts
can be found in the catalog for the linear
motion system used. When dimensioning
the drive, always take the motor/controller

combination into consideration as the
effective speed and maximum torque depend on the combination used. The selection tables can be found in the sections
referring to the different controllers.
Length estimate:
Excess travel = 2 P = 2 32 = 64 mm
L 1100 (from table)
Travelmax = ( stroke + 2 excess travel ) = 500 mm + 2 64 mm = 628 mm
vaverage =
effective stroke 0.5 m

=
= 0.5 m/s = 30 m/min
total time
1.0 s
According to the chart for maximum velocity, the permissible ball screw drive for
v = 30 m/min and L 1100 mm is:
32 x 20; 32 x 32
According to the chart maximum permissible drive torque and the motor/controller combination MDD 71C-N-040 with DKS1.1-W050A and overload factor
OF = 137% (Controllers catalog, page 36) Mperm ( 35 Nm) > MMmax (= 17.4 Nm):
Selected ball screw drive: KGT 32 x 20
Calculation
Length L
Acceleration torque MB
Mass moment of inertia Jtot
Travelmax = ( stroke + 2 excess travel ) = 500 mm + 2 40 mm = 580 mm

with excess travel = (2 P) = 2 20 = 40 mm
L = 1020 (from table)
Max. travel = 582 mm
(1)
MB = 0.8 MMmax Mf = 0.8 17.4 Nm - 1.21 Nm = 12.71 Nm
MMmax = 17.4 Nm < Mperm 35 Nm (from chart Max. perm. drive torque)
with JS = 2465 10-6 kgm2
(4)
Equations and data taken from catalog Ball Rail Tables

JK = 200 10-6 kgm2
Jfr = JS + JK + JB (is disregarded= (2465 + 200) 10-6 kgm2 = 2665 10-6 kgm2
For handling:
JM >
Jfr
>
6
2665 10-6
> 444 10-6 kgm2
6
JM = 11.90 kgcm2 = 1190 10-6 kgm2 (values from table on page 48)
1190 10-6 kgm2 > 444 10-6 kgm2 > condition met
Jtot = Jfr + JM = (2665 + 1190) 10-6 kgm2 = 3855 10-6 kgm2
90
RE 82 701/02.99
Speed n
n1 =
iv
150 m/min
1000 =
1000 = 2500 rpm
P
20 mm
(6)
v = 50 m/min = 0.833 m/s, i =1 (value from diagram maximum velocity)
Acceleration time th
( n 0.10472
) = 3855 10-6 (
M
2500 0.10472
) s = 0.0794 s (7)
12.71
50 m/min
v
=
= 10.50 m/s2
th 60 0.0794 s 60
(8)
th = Jtot
Acceleration a
a =
Acceleration distance sh
sh = 0.5 a th2 = 0.5 10.50 m/s2 (0.0794 s)2 = 0.0330 m = 33.0 mm
Discrete distance step sk

at constant velocity
sk = s - 2 sh = 500 mm - 2 33.0 mm = 434 mm
Constant velocity vk
vk = n P =
Discrete time step tk

at constant velocity
tk =
Total time t
t = 2 th + tk = 2 0.0794 s + 0.560 s = 0.719 s
Distance-time diagram
2500 rpm 20 mm
1000
(9)
= 50 m/min = 0.833 m/s
sk
0.434 m
=
= 0.560 s
vk
0.833 m/s
v (m/min)
50
25
0,1
th = 0,0794 s
sh = 33,0 mm
0,2
0,3
0,4
tk = 0,560 s
(sk = 434 mm)
t = 0,719 s
(s = 500 mm)
RE 82 701/02.99
91
0,5
0,6
0,7
t (s)
th = 0,0794 s
sh = 33,0 mm
Great care has been taken during the compilation of this

publication to ensure all the information contained is
accurate. We accept no responsibility however for any
damage resulting from incorrect or incomplete information contained.
For deliveries and other services in the course of commercial business, the general terms and conditions for
supplies and services contained in the valid price lists
and the confirmations of order apply.
As our products are constantly in the process of further
development, they are subject to alteration without
notice.
STAR, Ball Rail and
are trademarks registered for
Roller Rail is a trademark of
Reproduction of this document, even in extract form,
is only permitted with our approval.
Telephone
+49-9721-9 37-0
Telefax
(general)
+49-9721-9 37-275
Telefax
(direct)
+49-9721-9 37-350
www.rexroth-star.com
Controllers, Motors,
Electrical Accessories
RE 82 701/10.99
Printed in Germany - p 99/.././..
Printed on chlorine-free bleached paper
Deutsche Star GmbH

D-97419 Schweinfurt

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X

STAR Linear Motion Technology

Standard Ball Rail Systems

Roller Rail Systems

Ball Screw Drives

Linear Motion Systems

Linear Motion Slides

Rexroth Star GmbH

are trademarks registered for

Roller Rail is a trademark of

DKC Digital Controllers

Digital Controller DKC 11 / DKC 01

DKS Digital Positioning Controller

- DLC Positioning Interface

DDS Digital Controller Modules

- CLM Analog Positioning Module

- Technical Data and Dimension Drawings

Three-Phase Motor Data and Dimensions

Three-Phase Gear Motors with Integrated Frequency Inverter

Stepping Motor Power Output Section WD3-004 / WDM3-004

STAR step Positioning Controls

Drive Controls and Controllers

Linear Motion Systems

3-phase stepping motor

Digital positioning module

Digital controllers and

Power output section

Single-axis and multi-axis

knnen den jeweiligen Katalog des Fhrungssystems entnommen werden.

siehe Tabelle im jeweiligen Fhrungssystem-Katalog

Grundplatte fest, Tischteil verfhrt:

Tischteil fest, Grundplatte verfhrt:

Massentrgheitsmoment von System

MB = maximales Beschleunigungsmoment des Motors

mlin = linear bewegte

(MBreq + Mtot)2 tBreq 2 + Mtot2 tconst + Mtot2 tp

(4) JS= aus Katalog des Fhrungssystems

DKC Digital Controller

In addition to many other fields of application, the DKC is

Low power dissipation

Direct mains connection

The matched combinations of the DKC compact controller and

DKC 11.* / DKC 01.*

Built-in holding brake control

Software travel limitation

Incremental or absolute position actual value output

External reset possible

Maintenance-free synchronous motors

Enhanced operational reliability

Fast dynamic response

Automatic controller optimization

DKC Digital Controllers

1-phase 230 10%

Single-phase direct mains connection

Three-phase direct mains connection

3-phase 380 - 480 10%

For power ratings up to 1.1 kW, the

For power ratings up to 10 kW, the

Several controllers can be connected in

Fast dynamic response