dkc**.3-016 drive controllers

Electric Drivesand Controls

Hydraulics

Linear Motion andAssembly Technologies

Pneumatics

Service

Rexroth EcoDrive 03Drive ControllersDKC**.3-016

R911320340Edition 01

Instruction Manual

About this Documentation Rexroth EcoDrive 03

DOK-ECODR3-DKC16*UL***-IB01-EN-P

Rexroth EcoDrive 03

Drive Controllers

DKC**.3-016

Instruction Manual


120-1000-B363-01/EN

This documentation provides information on the installation and operationof the described products, by persons trained and qualified to work withelectrical installations.

Description ReleaseDate

Notes

Instruction Manual 03.2007 1st edition

2007.. Bosch Rexroth AG

Copying this document, giving it to others and the use or communicationof the contents thereof without express authority, are forbidden. Offendersare liable for the payment of damages. All rights are reserved in the eventof the grant of a patent or the registration of a utility model or design(DIN 34-1).

The specified data is for product description purposes only and may notbe deemed to be guaranteed unless expressly confirmed in the contract.All rights are reserved with respect to the content of this documentationand the availability of the product.

Bosch Rexroth AGBgm.-Dr.-Nebel-Str. 2 • D-97816 Lohr a. Main

Telephone +49 (0)93 52/40-0 • Tx 68 94 21 • Fax +49 (0)93 52/40-48 85

http://www.boschrexroth.com/

BRC/EDY4 (NN)

This document has been printed on chlorine-free bleached paper.

Title

Type of Documentation

Document Typecode

Internal File Reference

Purpose of Documentation

Record of Revisions

Copyright

Validity

Published by

Note

Rexroth EcoDrive 03 DKC**.3-016 Contents I


Contents

1 Important Notes 1-1

1.1 Safety Instructions ........................................................................................................................ 1-1

General Information................................................................................................................. 1-1

Contact with Electrical Parts.................................................................................................... 1-2

Handling and Assembly........................................................................................................... 1-2

Dangerous Movements ........................................................................................................... 1-2

Magnetic and Electromagnetic Fields ..................................................................................... 1-4

Hot Parts.................................................................................................................................. 1-4

1.2 Appropriate Use............................................................................................................................ 1-4

2 Identification 2-1

2.1 Type Code .................................................................................................................................... 2-1

2.2 Type Plates ................................................................................................................................... 2-1

2.3 Scope of Supply............................................................................................................................ 2-2

3 Ratings and Dimensions 3-1

4 Reference Documentations 4-1

4.1 Overview....................................................................................................................................... 4-1

5 Instructions for Use 5-1

5.1 Overcurrent Protection.................................................................................................................. 5-1

5.2 Connections.................................................................................................................................. 5-1

Wiring Diagram........................................................................................................................ 5-1

Connection Diagram................................................................................................................ 5-2

X1, Connections for control voltage......................................................................................... 5-3

Connection of Control Interfaces and Terminals ..................................................................... 5-6

X5, Motor and Mains Connections .......................................................................................... 5-6

X6, Motor temperature monitoring and holding brakes ........................................................... 5-8

X10, EcoX Expansion interface............................................................................................. 5-12

XE1, XE2 Protective conductor connections for motor and mains........................................ 5-13

XS1, XS2, XS3 Shield Connections ...................................................................................... 5-14

H1, S1, S2, S3: Diagnostic display, Reset key, Address switch ........................................... 5-14

5.3 Installation................................................................................................................................... 5-15

General Information on How to Install the Drive Controller ................................................... 5-15

Sizing of Enclosure and Control Cabinet............................................................................... 5-16

6 Index 6-1

II Contents Rexroth EcoDrive 03 DKC**.3-016


Rexroth EcoDrive 03 DKC**.3-016 Important Notes 1-1


1 Important Notes

1.1 Safety Instructions

General Information• Do not attempt to install or commission this device without first reading

all documentations provided with the product. Read and understandthese safety instructions and all user documentation prior to workingwith the device. If you do not have the user documentation for thedevice, contact your responsible Bosch Rexroth sales representative.Ask for these documents to be sent immediately to the person orpersons responsible for the safe operation of the device.

• If these documentations contain some information you do notunderstand, it is absolutely necessary that you ask Bosch Rexroth forexplanation before you start working on or with the devices.

• Only persons who are trained and qualified for the use and operationof the device may work on this device or within its proximity. Thepersons are qualified if they have sufficient knowledge of theassembly, installation and operation of the equipment as well as anunderstanding of all warnings and precautionary measures noted inthis documentation.

• Only trained, instructed and qualified persons are allowed to switchelectrical circuits and devices on and off in accordance with technicalsafety regulations, to ground them and to mark them according to therequirements of safe work practices. These persons must haveadequate safety equipment and be trained in first aid.

• Technical data, connections and operational conditions are specified inthe reference documentations for the product and must be followed atall times.

• If the products take the form of hardware, then they must remain intheir original state, in other words, no structural changes are permitted.It is not permitted to decompile software products or alter sourcecodes.

• Do not mount damaged or faulty products or use them in operation.

• Only use spare parts and accessories approved by Bosch Rexroth.

• Follow all safety regulations and requirements for the specificapplication as practiced in the country of use.

• If the device is resold, rented and/or passed on to others in any otherform, these safety instructions must be delivered with the device in theofficial language of the user's country.

• Proper and correct transport, storage, assembly and installation aswell as care in operation and maintenance are prerequisites foroptimal and safe operation of this device. Observe the data containedin the corresponding product documentations.

WARNING

Improper use of these devices, failure to follow the safety instructions in thisdocument or tampering with the product, including disabling of safety devices, mayresult in material damage, bodily harm, electric shock or even death!⇒ Observe the following safety instructions!

1-2 Important Notes Rexroth EcoDrive 03 DKC**.3-016


Contact with Electrical Parts

DANGER

High electrical voltage! Danger to life, electric shock and severe bodily injury!• Follow general construction and safety regulations when working on power installations.

• Before switching on the device, the equipment grounding conductor must have beennon-detachably connected to all electrical equipment and motors in accordance with theconnection diagram.

The equipment grounding conductor of the electrical equipment and the units must benon-detachably and permanently connected to the power supply unit at all times. Theleakage current is greater than 3.5 mA.

Over the total length, use copper wire of a cross section of a minimum of 10 mm2 forthis equipment grounding connection!

• Before working with electrical parts with voltage potentials higher than 50 V, the devicemust be disconnected from the mains voltage or power supply unit. Provide a safeguardto prevent reconnection.

• Wait 30 minutes after switching off power to allow capacitors to discharge beforebeginning to work. Measure the electric voltage on the capacitors before beginning towork to make sure that the equipment is safe to touch.

• Never touch the electrical connection points of a component while power is turned on.

• Install the covers and guards provided with the equipment properly before switching thedevice on. Before switching the equipment on, cover and safeguard live parts safely toprevent contact with those parts.

• A residual-current-operated circuit-breaker or r.c.d. cannot be used for electric drives!Indirect contact must be prevented by other means, for example, by an overcurrentprotective device according to the relevant standards.

Handling and Assembly

CAUTION

Risk of injury by improper handling! Bodily injury by bruising, shearing, cutting, hitting!• Observe the general construction and safety regulations on handling and assembly.

• Use suitable devices for assembly and transport.

• Avoid jamming and bruising by appropriate measures.

• Always use suitable tools. Use special tools if specified.

• Use lifting equipment and tools in the correct manner.

• If necessary, use suitable protective equipment (for example safety goggles, safety shoes,safety gloves).

• Do not stand under hanging loads.

• Immediately clean up any spilled liquids because of the danger of skidding.

Dangerous MovementsDangerous movements can be caused by faulty control of connectedmotors. Some common examples are:

• improper or wrong wiring of cable connections

• incorrect operation of the equipment components

• wrong input of parameters before commissioning

• malfunction of sensors, encoders and monitoring devices

• defective components

• software or firmware errors

Rexroth EcoDrive 03 DKC**.3-016 Important Notes 1-3


Dangerous movements can occur immediately after equipment isswitched on or even after an unspecified time of trouble-free operation.

The monitoring in the drive components will normally be sufficient to avoidfaulty operation in the connected drives. Regarding personal safety,especially the danger of bodily harm and material damage, this alonecannot be relied upon to ensure complete safety. Until the integratedmonitoring functions become effective, it must be assumed in any casethat faulty drive movements will occur. The extent of faulty drivemovements depends upon the type of control and the state of operation.

DANGER

Dangerous movements! Danger to life, risk of injury, severe bodily harm or materialdamage!• For the above reasons, ensure personal safety by means of qualified and tested higher-

level monitoring devices or measures integrated in the installation.

They have to be provided for by the user according to the specific conditions within theinstallation and a hazard and fault analysis. The safety regulations applicable for theinstallation have to be taken into consideration. Unintended machine motion or othermalfunction is possible if safety devices are disabled, bypassed or not activated.

To avoid accidents, bodily harm and/or material damage:

• Keep free and clear of the machine’s range of motion and moving parts. Possiblemeasures to prevent people from accidentally entering the machine’s range of motion:

– use safety fences

– use safety guards

– use protective coverings

– install light curtains or light barriers

• Fences and coverings must be strong enough to resist maximum possible momentum.

• Mount the emergency stop switch in the immediate reach of the operator. Verify that theemergency stop works before startup. Don’t operate the device if the emergency stop isnot working.

• Isolate the drive power connection by means of an emergency stop circuit or use a safetyrelated starting lockout to prevent unintentional start.

• Make sure that the drives are brought to a safe standstill before accessing or entering thedanger zone.

• Additionally secure vertical axes against falling or dropping after switching off the motorpower by, for example:

– mechanically securing the vertical axes,

– adding an external braking/ arrester/ clamping mechanism or

– ensuring sufficient equilibration of the vertical axes.

• The standard equipment motor brake or an external brake controlled directly by the drivecontroller are not sufficient to guarantee personal safety!

• Disconnect electrical power to the equipment using a master switch and secure the switchagainst reconnection for:

– maintenance and repair work

– cleaning of equipment

– long periods of discontinued equipment use

• Prevent the operation of high-frequency, remote control and radio equipment nearelectronics circuits and supply leads. If the use of such devices cannot be avoided, verifythe system and the installation for possible malfunctions in all possible positions of normaluse before initial startup. If necessary, perform a special electromagnetic compatibility(EMC) test on the installation.

1-4 Important Notes Rexroth EcoDrive 03 DKC**.3-016


Magnetic and Electromagnetic Fields

WARNING

Health hazard for persons with heart pacemakers, metal implants and hearing aids inproximity to electrical equipment!• Persons with heart pacemakers and metal implants are not permitted to enter following

areas:

– Areas in which electrical equipment and parts are mounted, being operated orcommissioned.

– Areas in which parts of motors with permanent magnets are being stored, repaired ormounted.

• If it is necessary for somebody with a pacemaker to enter such an area, a doctor mustbe consulted prior to doing so. The interference immunity of present or future implantedheart pacemakers differs greatly, so that no general rules can be given.

• Those with metal implants or metal pieces, as well as with hearing aids must consult adoctor before they enter the areas described above.Otherwise health hazards may occur.

Hot Parts

CAUTION

Hot surfaces at motor housings, on drive controllers or chokes! Danger of burns!• Do not touch surfaces of device housings and chokes in the proximity of heat sources!

Danger of burns!

• Do not touch housing surfaces of motors! Danger of burns!

• According to operating conditions, temperatures can be higher than 60 °C (140 °F)during or after operation.

• Before accessing motors after having switched them off, let them cool down for asufficiently long time. Cooling down can require up to 140 minutes! Roughly estimated,the time required for cooling down is five times the thermal time constant specified in theTechnical Data.

• Wear safety gloves or do not work at hot surfaces.

• For certain applications, the manufacturer of the end product, machine or installation,according to the respective safety regulations, has to take measures to avoid injuriescaused by burns in the end application. These measures can be, for example: warnings,guards (shielding or barrier), technical documentation.

1.2 Appropriate Use

This product may only be used for the applications mentioned in thereference documentations (see chapter “Reference Documentations”)and under the described application, ambient and operating conditions.

Rexroth EcoDrive 03 DKC**.3-016 Identification 2-1


2 Identification

2.1 Type Code

Note: The following figure illustrates the basic structure of the typecode. Our sales representative will help you with the currentstatus of available versions.

DKC 03.3 - 040 - 7 - FW

DKC

TL0001F1.FH7

Drive controller

Type code fields: Example:

3

7

FW

Voltage category

Firmware

Version

A firmware specifying the functions of thedrive must be ordered separately.

xxSeries

Type current

40 A100 A

040100200200 A

16 A 016

Fig. 2-1: Type code

2.2 Type Plates

Basic Unit

TS0012F1.FH7

Serial number Hardware index

Barcode

Fig. 2-2: Type plate

Unit type

TS0014F1.FH7

Production week

Serial number Hardware index Barcode

Part number Device type

Fig. 2-3: Type plate – DKC example

2-2 Identification Rexroth EcoDrive 03 DKC**.3-016


2.3 Scope of Supply

Type Connectors - type independent X.. Connectors - type dependent X..

1 2 3 4 5 6 10 15 20 21 30 40 41 50 60 210

DKC01.3-***-7 X X X X X X

DKC02.3-***-7 X X X X X

DKC03.3-***-7 X X X X X

DKC04.3-***-7 X X X X X

DKC05.3-***-7 X X X X X

DKC06.3-***-7 X X X X X X

DKC21.3-***-7 X X X X X

DKC22.3-***-7 X X X X X

Fig. 2-4: Connectors for DKC**.3-016-7-FW included in the scope of supply

Rexroth EcoDrive 03 DKC**.3-016 Ratings and Dimensions 3-1


3 Ratings and Dimensions

Description Symbol Unit DKC**.3-016

listing according UL-standard (UL) UL 508 C

listing according CSA-standard (UL) Canadian National Standard(s) C22.2No. 14-05

UL files (UL) E134201

pollution degree (UL) Use in a pollution degree 2environment

maximum ambient temperature with nominal data (UL) Tamax °C 45

maximum ambient temperature with reduced nominaldata (UL) Tamax_red °C 55

Weight m kg 3.2

Device height (UL) 1) H mm 287

Device depth (UL) 2) T mm 229

Device width (UL) 3) B mm 65

minimum distance on the top of the device 4) dtop mm 150

minimum distance on the bottom of the device 5) dbot mm 80

rated control voltage input (UL) 6) UN3 V 24 (±5%)

rated power consumption control voltage input withoutholding brake, without control section atUN3 = DC 24 V (UL) 7)

PN3 W 17

short circuit current rating, SCCR, symmetricalamperes (UL) 8) ISCCR A rms 42000

rated input voltage, power (UL) 9) V 200 … 480

tolerance rated input voltage (UL) % ±10

input number of phases (UL) 1 × AC, 3 × AC

input frequency (UL) fLN Hz 50 … 60

tolerance input frequency (UL) % ±2

maximum input current (UL) 10) IL_cont A 1.7

branch circuit protection fuse (UL) 11) 2

field wiring material (UL) 12) Use 60/75 °C copper wire only, useclass 1 wire only or equivalent

required wire size according UL 508 A (internal wiring);at IL_cont (UL) 13) ALN AWG 16

maximum output voltage (UL) Uout V 800

output number of phases (UL) 3

maximum output current (UL) Iout_max A 16

maximum output frequency (UL) fout Hz 1000

3-2 Ratings and Dimensions Rexroth EcoDrive 03 DKC**.3-016


Description Symbol Unit DKC**.3-016

power dissipation at continuous current Iout_cont andcontinuous DC bus power PDC_cont respectively (UL) 14) PDiss_cont W 130

1) 2) 3) housing dimension; see related dimension sheet also4) 5) see fig. "Air inlet and outlet of drive controller"6) observe supply voltage for motor holding brakes7) find value for control section in project planning manual8) Suitable for use on a circuit capable of delivering not more than this

SCCR value, 600 V AC or less. The drive series shall be used withlisted AC input line fuses or listed circuit breakers specified in thisdocumentation.

9) Mains input L1, L2, L310) at PDC_cont11) class J branch circuit fuse12) find value for tightening torque in project planning manual, electrical

terminals13) copper wire; PVC-insulation (conductor temperature 90 °C); Table

13.5.1; Ta ≤ 40 °C14) plus dissipation of braking resistor

Abb. 3-1: UL ratings and dimensions

A: air intakeB: air outletC: mounting surface in control cabinetdtop: distance topdbot: distance bottom

Fig. 3-2: Air intake and air outlet at drive controller

Distances

Rexroth EcoDrive 03 DKC**.3-016 Reference Documentations 4-1


4 Reference Documentations

4.1 Overview

Title Type Document Typecode

Servo Applications with 1,5 s AccelerationTime

Selection lists DOK-ECODR3-SERV-GEN***-AUxx-MS-P

Servo Applications with 400 ms AccelerationTime

Selection lists DOK-ECODR3-SERV-WZM***-AUxx-MS-P

Main drives with 2AD-, ADF and 1MB-motors Selection lists DOK-ECODR3-MAIN*WZM***-AUxx-MS-P

List of Connecting Cables for DIAX04 andECODRIVE03

Selection lists DOK-CONNEC-CABLE*STAND-AUxx-EN-P

ECODRIVE03 Drive for Machine ToolApplications With SERCOS-, Analog andParallel interface

Functional Description DOK-ECODR3-SMT-01VRS**-FKxx-EN-P


Functional Description DOK-ECODR3-SMT-02VRS**-FKxx-EN-P

ECODRIVE03 Drive for General AutomationWith SERCOS-, Analog and Parallel interface

Functional Description DOK-ECODR3-SGP-01VRS**-FKxx-EN-P

ECODRIVE03 Drive for General AutomationWith Fieldbus-Interfaces

Functional Description DOK-ECODR3-FGP-01VRS**-FKxx-EN-P





LWL Handling Application Manual DOK-CONNEC-CABLE*LWL-AWxx-EN-P

Electromagnetic Compatibility (EMC) in Driveand Control Systems

Project Planning Manual DOK-GENERL-EMV********-PRxx-EN-P

Digital AC Motors MKD Project Planning Manual DOK-MOTOR*-MKD********-PRxx-EN-P

Digital AC Motors MHD Project Planning Manual DOK-MOTOR*-MHD********-PRxx-EN-P

MKE Digital AC Motors for potentiallyexplosive areas

Project Planning Manual DOK-MOTOR*-MKE********-PRxx-EN-P

2AD AC Motor Project Planning Manual DOK-MOTOR*-2AD********-PRxx-EN-P

ADF Main Spindle Motors Project Planning Manual DOK-MOTOR*-ADF********-PRxx-EN-P

1MB Frameless Spindle Motor Project Planning Manual DOK-MOTOR*-1MB********-PRxx-EN-P

Synchronous MBS Kit Spindle Motors Project Planning Manual DOK-MOTOR*-MBS********-PRxx-EN-P

LAR 070-132 Gehäuse-Linearmotoren Selection and ProjectPlanning

DOK-MOTOR*-LAR********-AWxx-DE-P

LAF050 – 121 Linear Motors Selection and ProjectPlanning

DOK-MOTOR*-LAF********-AWxx-EN-P

Linear Synchronous Direct Drives LSF Project Planning Manual DOK-MOTOR*-LSF********-PRxx-EN-P

AC Drive Units in Personnel ConveyorSystems

Application Manual DOK-GENERL-ANTR*PERSON-ANxx-EN-P

AC Drive Units in Hazardous Areas (Expl.Protection)

Application Manual DOK-GENERL-ANTR*EXPLOS-ANxx-EN-P


Troubleshooting Guide DOK-ECODR3-SMT-01VRS**-WAR*-EN-P

4-2 Reference Documentations Rexroth EcoDrive 03 DKC**.3-016


Title Type Document Typecode

ECODRIVE03 Drive for Machine ToolApplications With SERCOS-, Analog andParallelinterface

Troubleshooting Guide DOK-ECODR3-SMT-02VRS**-WAR*-EN-P

ECODRIVE03 Drive for General AutomationWith SERCOS-, Analog and Parallel interface

Troubleshooting Guide DOK-ECODR3-SGP-01VRS**-WAxx-EN-P


Troubleshooting Guide DOK-ECODR3-FGP-01VRS**-WAxx-EN-P





1) In the document typecodes, "xx" is a wild card for the current editionof the documentation (example: "PR01" is the first edition of aProject Planning Manual)

Fig. 4-1: Documentations - Overview

Rexroth EcoDrive 03 DKC**.3-016 Instructions for Use 5-1


5 Instructions for Use

5.1 Overcurrent Protection

Branch circuit protection has to be provided externally according to themaximum values (voltage and current or voltage and percent of FLA ofthe fuses [FLA: Full Load Ampacity]).

5.2 Connections

Wiring Diagram

Fig. 5-1: Overview of individual components

5-2 Instructions for Use Rexroth EcoDrive 03 DKC**.3-016


Connection Diagram

Rexroth EcoDrive 03 (DKC**.016)

Fig. 5-2: Total connection diagram for DKC**.3-016



X1, Connections for control voltage

Technical description of connector

Ap5382f1.FH7

12

3

45

6

Fig. 5-3: Connector X1

Type No. of pins Design

Spring contact 2 x 3 Bushing on connectorFig. 5-4: Design

Cross sectionsingle wire

[mm²]

Cross sectionmulti core wire

[mm²]

Wire sizein AWG

Gauge no.:

0,2-2,5 1,5-2,5 16-12Fig. 5-5: Connection cross section

24V control voltage supply (+24V and 0V)

AP5392F1.FH7

��

�

�

��

��

�

device-external device-internal

connection for control voltage

Fig. 5-6: Connections for control voltage

Voltage at X1/1 against X1/2:

Current or power consumption X1/1:

see chapter "Ratings andDimensions"

Reverse voltage protection: Via allowed voltage rangeusing internal protection

diodes

Note: Strong mechanical influence on the test tap of the terminalscan increase the transition resistance and destroy theterminals.

Note: The input 0 V is connected directly to the device potential. Theutilization of an insulation monitoring for +24 V and 0 V againstdevice is therefore not possible!

wire cross section: min. 1 mm²

wire routing: parallel if possible

Max. allowed inductance between 24V sourceand X1:

100 µH(equals about 2 x 75 m)

Illustration:

Design:

Connection cross section:

Connection+24V and 0V:

Connection loads+24V and 0V:

wire+24V and 0V:



Note:

• Exceeding allowed control voltage generates errormessage "+24 volt error". (=> See also functional firmwaredescription.)

• Control voltage failure causes the running motor to coasttorque-free (without brake).

DANGER

Dangerous movements due to unbrakedcoasting of motor with control voltage failure!⇒ Personnel should not remain within the area of the

machine with moving parts. Possible preventivesteps against unauthorized access are:– protective fencing– bars– covers– light barriers

⇒ The fences must be able to withstand the maximumpossible force that the machine can generate.

Drive halt (AH) and Drive enable (RF)

Note:

• Inputs work with inactive bus communication.

• Inputs don't work with active bus communication (SERCOSinterface, Profibus-DP, ...).

AP5393f1.FH7

��

�

�

�

��

�

�

drive halt

drive enable


Fig. 5-7: Connections for drive halt and drive enable

R1 R3

R2 C1

In

Ap5183f1.fh7

SchematicsR1: 10kR2: 3k3R3: 10kC1: no data

Fig. 5-8: Input circuit

ConnectionAH and RF:

Input circuitAH and RF:



Input voltage:

High

Low

min.

16 V

-0.5 V

max.

30 V

3 V

Input resistance 13.3 kOhm ±5%

Reaction time See functional firmware descriptionFig. 5-9: Inputs

The drive halt function is used to bring an axis to standstill with definedacceleration and jerk (see functional firmware description).

The input drive enable (RF) activates the drive with a 0-1 edge.

Note: If the inputs are controlled by a power supply other than theDC24 volt supply of the DKC, then the reference lead of theother power supply must be connected to X1.2 (0 V).

Ready to operate contact Bb

AP5394f1.FH7

��

�

�

�

�

�

��

��

ready for operation


ready for operation

Fig. 5-10: Connections for ready to operate contact

Max. switching voltage: DC 40 V

Max. switching current: DC 1 A

Max. continuous current: DC 1 A

Minimum contact load: 10 mA

Guaranteed number of switching operationsat max. time constant of load < 50 ms:

250,000

The Bb contacts opens:

• if control voltage for DKC is not applied

• if 24 volts not present at the emergency stop input when the E-stopfunction is activated (depends on parameterization, see functiondescription).

• With an error in the drive (depends on parameterization, see functionalfirmware description: "Power off on error").

WARNING

Damage possible if Bb contact not connected !The ready to operate contact Bb acknowledges the driveis ready for mains voltage.

⇒ Integrate Bb contact as per "Control Circuits for theMains Connection" (see Project Planning manual).

⇒ The evaluation of the Bb contact by a PLC may notcause any operating delay of more than 10 ms.

InputsAH and RF:

AH:

RF:

ConnectionBb:

Loadability of the connectionBb:

Switching statesBb:



Connection of Control Interfaces and Terminals

See Project Planning Manual for more details.

X5, Motor and Mains Connections

DANGER

Lethal electric shock caused by live parts withmore than 50 V!⇒ Before working on the drive controller, switch off the

power supply via the main switch or the fuse.⇒ Always mount or dismount both connectors (motor

connector and mains connector) on the drivecontroller at the same time.

⇒ Connect the protective conductor connections XE1and XE2 to the protective conductor system of thecontrol cabinet. Check the continuity of the protectiveconductors from the mains connection to theconnected motors.

⇒ Observe information in chapter "Important Notes"


��

��


Note:

• To pull off the connectors, loosen the barbs.

• The maximum number of insertion/withdrawal cycles islimited to 15.


connection block 2 x 3 bushing on connectorFig. 5-12: Design


[mm²]

max. connectablecross section

[mm²]

max. Wire sizein AWG

gauge no.:

1,5 1,5 16Fig. 5-13: Connection cross section

Illustration:

Design:




Motor connection

AP5398f1.FH7

X5device-external device-internal

motor connectionA1

A2

A3

Fig. 5-14: Motor connections

Use Rexroth motor power cables to connect motor and controller.

Note: For technical data on connections and cross sections, see themotor Project Planning Manual.

Cable length:

Maximum length equals 35 m:

• With two connections between controller and motor(e.g., plugs at exit of control cabinet and at machine)

• Standard cables from Rexroth and

• Ambient temperatures of ≤ 40 °C per EN 60 204

• Switch frequency of 4 kHz

Maximum allowed capacitance per unit length at A1, A2, A3:

• with regard to ground: 0.5 nF/m

• cable to cable: 0.5 nF/m

Maximum allowed inductance per unit length an A1, A2, A3:

• 100 nH/m

To maintain EMC values, the motor cable length is limited with aswitching frequency of > 4 kHz. It is largely dependent on the applicationand ambient conditions at the installation and machine.

A guide value is listed below:

Cycle frequency drivecontroller

Max. length forclass B, EN 55011

Max. length forclass A, EN 55011

standard setting switchingfrequency 4 kHz

35 m 35 m

parameter setting switchingfrequency 8 kHz

35 m 35 m

Fig. 5-15: Guide value for maximum motor cable lengths

WARNING

No guarantee!If third party cables are used, then the guarantee isforfeited for the entire system.⇒ Use Rexroth cables!

XE1

ConnectionMotor:

CableMotor:

Protective conductor connection



Mains connectionsThe mains connector serves as the connection of the drive controller withthe power supply.

AP5399f1.FH7

L1

L2

L3

L1

Nn.c.


X5

Fig. 5-16: Single-phase mains connection

AP5400f1.FH7

X5

L1

L2

L3

L1

L2

L3


Fig. 5-17: Three-phase mains connection

Note: Mains connections should not be daisy-chained between theunits (intermediate connectors for the supply source should beused).

XE2

X6, Motor temperature monitoring and holding brakes


Ap5382f1.FH7

12

3

45

6





[mm²]


[mm²]

Wire sizein AWG

Gauge no.:

0.2-2.5 1.5-2.5 16-12Fig. 5-20: Connection cross section

Single-phase mains connection:

Three-phase mains connection:

Protective conductor connection

Illustration:

Design:




CAUTION

Damages by exchanging the connectors X6.1-3and X6.4-6!⇒ Do not exchange connectors X6.1-3 and X6.4-6.⇒ Only use lines with sufficient cross section.⇒ Strong mechanical influence on the test tap of the

terminals can increase the transition resistance anddestroy the terminals.

Motor temperature monitoring (TM+, TM)Connections TM+ and TM- are used to evaluate the temperature ofconnected Rexroth motors. These are equipped with a temperature-dependent resistor (either PTC or NTC dependent on the motor type) tomonitor temperature. The connection leads are in the motor power cable.

AP5383F1.FH7

X61

2TM+

TM-3

4

5

6

motor temperature monitoring


Fig. 5-21: Motor temperature monitoring

AP5326F1.FH7

G

R

TM+

TM-

U

Drive Controller MOTOR

SchematicsU: approximately 5VR: approximately 2k

Fig. 5-22: Motor temperature evaluation

Note: Connections TM+ and TM- are only to be used with Rexrothmotors.

⇒ See also functional firmware description: "Temperature monitoring".

ConnectionmonitoringTM+, TM-:

Motor temperature evaluation:



Holding brake (BR+, BR-)

DANGER

Dangerous movements! Danger to personnelfrom falling or dropping axes!⇒ The standard equipment motor brake or an external

brake controlled directly by the servo drive are notsufficient to guarantee the safety of personnel!

⇒ Personnel safety must be acquired with higher-ranking procedures:

Dangerous areas should be blocked off with fencesor grids.

Secure vertical axes against falling or slipping afterswitching off the motor power by, for example:- Mechanically securing the vertical axes

- Adding an external brake / clamping mechanism

- Balancing and thus compensating for the verticalaxes mass and the gravitational force

These control the holding brakes in the connected motors.

For the switching performance, see function description.

To connect external loads note allowed contact loads.

AP5384F1.FH7

X61

2

3 BR+

4

BR-5

6

UB

0VB

holding brake+

voltage connection for brake


holding brake-

Fig. 5-23: Holding brake and voltage connection

Loadability of connections BR+, BR-:

max. switching voltage: DC 36 V

max. switching current: DC 1 A

max. continuous current: DC 1 A

Minimum contact load: 100 mV

Guaranteed number of switches atmax. time constant of load < 50 ms(LBremse/(24V/IBremse)):

unlimited (electronic contact free ofwear)

Short-circuit and overload protection inthe row to the contact

present

Voltage connection for brakes

Note: The motor holding brake is not supplied by the controller.Given one voltage source for brake and control voltage, useparallel leads from the voltage source. Note the voltage rangefor the motor holding brake according to the motor projection.

ConnectionBR+, BR:



Ap5385f1.fh7

X1

X6

24V

to the centralground

Fig. 5-24: Shared voltage source for brakes and control voltage supply

Note: Looping through the voltages to other drive controllers isimpossible. Other drive controllers have to be connected inradial arrangement around the voltage source.

max. voltage at X6.4 against X6.5: DC 36 V

current consumption at X6.3 and neededsupply voltage:

see "Technical data" brake inthe motor manual

wire cross section: min. 1 mm²

voltage resistance of single wire to ground > 750 V(e.g.: litz wires - H07)

wire routing parallel if possible(twisted)

max. inductance between 24 V sourceand X6

100 µH(equals about 2 x 75 m)

Motor holding brakeThe controller controls the holding brake.

Supply voltage, current consumption, linking, separating time, holdingtorque, etc. see motor manual.

Voltage connection for brakeson DKC:

wirevoltage connection for brake:

Controlling the motor holdingbrake:

Technical dataMotor holding brake:



Basic connection of motor power, holding brake andmotor temperature monitoring

AP5387F1.FH7

AC-MotorM3

U1

V1

W1

X1 X2

T1

T2

U

BR

-

BR

+3 41 2

A1 A2 A3

X65 6

TM

+

TM

-

BR

+

BR

-

UB

0VB

24VExt

0VExt

DKC

XE1

X5_M

24VXS1

Temperaturedependent resistance

Holdingbrake

Fig. 5-25: Connection of motor cable, holding brake and temperature monitorfor motors with connector box

Note: The cable designations and all details on making cables areoutlined in the cable or motor document.

X10, EcoX Expansion interface

Note: EcoX allows:

• synchronizing drives and I/O modules

• connecting up to 2 modules with 16 digital inputs andoutputs each per drive controller

• transmitting a command value from one drive controller toa maximum of three other drive controllers


Ap5268f1.FH7

12

3

45

6





[mm²]


[mm²]

Wire sizein AWG

gauge no.:

0.2-2.5 0.2-1.5 24-16Fig. 5-28: Connection cross section

Illustration:

Design:




Expansion interface

AP5376F1.FH7

device external device internal

X10123

4

56

IAN+

0VIAN-

IAN+IAN-0V

IAN+

IAN-

Fig. 5-29: Expansion interface

drive orE/A-

module

drive orE/A-

moduledrive

120 R120 R

IAN+

IAN-

EcoX bus

3,5V

2,5V

1,5V

voltage

timedominantrecessive

IAN+

IAN-

recessive

SV5179F1.FH7

Fig. 5-30: EcoX interface

max. bus length l: 20 m

bus terminating resistors on both ends of thebus cable

2 x 120 R / 250 mW

XE1, XE2 Protective Conductor Connections for Motor and Mains

DANGER

Lethal electric shock caused by live parts withmore than 50 V!⇒ Connect the protective conductor connections of the

drive controller to the protective conductor system ofthe control cabinet.

⇒ Cross section of protective conductor: > 10 mm²(Reason: high leakage currents (EN 50178/1998,section: 5.3.2.1)

⇒ Check the continuity of the protective conductorsfrom the mains connection to the connected motors.



screw-in connection 2 x 1 screw-in connection forring terminals M5

Fig. 5-31: Design

ConnectionExpansion interface:

EcoX-Bus:

Bus cable:

Design:



min. tightening torque[Nm]

max. tightening torque[Nm]

2.5 3.0

Fig. 5-32: Tightening torque


[mm²]

Max. connectablecross section

in mm²

Max. wire sizein AWG

gauge no.:

-- 25 --Fig. 5-33: Connection cross section

AllocationMotor

Mains

XS1, XS2, XS3 Shield Connections

XS1Connection for shield:

• Total motor cable shield

• Holding brake

• Motor temperature monitoring

XS2Connection for shields of cables at X1 and those for the commandcommunication interfaces.

XS3Connection for shields of cables at X3 and X10.

6 - 15 mm (for all shield connections)

Note: Always connect the shield connections of the cables(especially of the motor cables) with a large contact surface.

H1, S1, S2, S3: Diagnostic display, Reset key, Address switch

Fig. 5-34: H1: Diagnostic display, S1: Reset key, S2, S3: Address switch

H1Number of diagnostic messages (errors and operating states).

Tightening torque:


XE1

XE2

Allowed outside diameter:



S1• Key for resetting diagnostic displays of errors

• Key for updating firmware

S2, S3Switch for setting the drive address.

Two decade switches are used to set the drive address. It can be set toany number between 1 and 99.

Example:

Switch setting S3 = 9 (value of tens)

Switch setting S2 = 1 (value of ones)

Drive address = 9 * 10 + 1 = 91

Note: The address is not set at delivery.

The setting of switches S2 and S3 depends on the model,firmware and the drive address wanted.

⇒ see functional firmware description

5.3 Installation

General Information on How to Install the Drive ControllerDamage can be caused to the drive controller or circuit boards ifelectrostatic charging present in people and/or tools is discharged acrossthem. Therefore, please note the following information:

CAUTION

Electrostatic charges can cause damage toelectronic components and interfere with theiroperational safety!⇒ Exposed conductive parts coming into contact with

components and circuit boards must be dischargedby means of grounding. Otherwise errors may occurwhen triggering motors and moving elements.

Such exposed conductive parts include:

• the copper bit when soldering

• the human body (ground connection caused by touching a conductive,grounded item)

• parts and tools (place them on a conductive support)

Endangered components may only be stored or dispatched in conductivepackaging.

Note: Rexroth connection diagrams are only to be used forproducing installation connection diagrams. The machinemanufacturer’s installation connection diagrams must be usedfor wiring the installation!

Address switch S2, S3;Drive address



• Lay signal lines separately from the load resistance lines because ofthe occurrence of interference.

• Transmit analog signals (e.g. command values, actual values) viashielded lines.

• Do not connect mains, DC bus or power leads to low voltages or allowthem to come into contact with these.

• When carrying out a high voltage test or an applied-overvoltagewithstand test on the machine’s electrical equipment, disconnect allconnections to the devices. This protects the electronic components(allowed in accordance with EN 60204-1). During their routine testing,Rexroth drive components are tested for high voltage and insulation inaccordance with EN 50178.

CAUTION

Risk of damage to the drive controller byconnecting and disconnecting live connections!⇒ Do not connect and disconnect live connections.

Sizing of Enclosure and Control Cabinet

Control Cabinet with Multiple-Line Structure

Note: Particular attention should be paid to the maximum allowed airintake temperature of components when they are arranged inmultiple lines in the control cabinet. Where necessary, coolingair guides are to be provided with blowers specially used forthis purpose.

air guideaddit-ionalblower

conveying direction of heated airin flow-off area

conveying direction of heated airin flow-off area

intake area of cooling air forupper device line

intake area of cooling air forlower device line

outlet air tocooling unit

supply airfrom coolingunit



Fig. 5-35: Example of arrangement for multiple-line structure with components

Arrangement of Cooling Units

CAUTION

Possible damage to the drive controllerOperational safety of the machine endangered!Note the following instructions!

Due to the operating principle, condensation water is formed when coolingunits are used. For this reason, please observe the following information:

• Always position cooling units in such a way that condensation watercannot drip onto electronic equipment in the control cabinet.

• Position the cooling unit in such a way that the blower of the coolingunit does not spray accumulated condensation water onto electronicequipment.

electronicequipment

Eb0001f1.fh7

incorrectcorrect

warm cold

Cooling system

Cabinet

warm cold

Air duct

electronicequipment

Cabinet

Cooling system

Fig. 5-36: Arranging the cooling unit on the control cabinet

Avoiding Dripping or SprayedWater



electronic

equip.

Eb0002f1.fh7

incorrect

coolingunit

control cabinet

air inflow

air outflow

correct

control cabinet

air inflow

airduct

electronic

equip.

coolingunit

Fig. 5-37: Arranging the cooling unit at the front of the control cabinet

Moisture condensation occurs when the temperature of the device islower than the ambient temperature.

• Set cooling units with temperature adjustment to the maximumsurrounding temperature and not lower!

• Set cooling units with follow-up temperature in such a way that theinterior temperature of the control cabinet is no lower than thetemperature of the surrounding air. Set the temperature limitation tothe maximum surrounding temperature!

• Only use well-sealed control cabinets so that moisture condensationcannot arise as a result of warm and moist external air entering thecabinet.

In the event that control cabinets are operated with the doors open(commissioning, servicing etc.) it is essential to ensure that after thedoors are closed the drive controllers cannot at any time be cooler thanthe air in the control cabinet, as otherwise moisture condensation canoccur. For this reason sufficient circulation must be provided inside thecontrol cabinet to avoid pockets of heat.

Avoiding Moisture Condensation

Rexroth EcoDrive 03 DKC**.3-016 Index 6-1


6 Index

224V control voltage supply (DKC**.3-016) 5-3

AAddress switch (DKC**.3-016) 5-14Appropriate Use 1-4

BBb 5-5

DKC**.3-016 5-5

CConnection cross section

X1 5-3X10 5-12

Connection Diagram 5-2Connection length

X10 5-13Connections 5-1control cabinet

with multiple-line structure 5-16cooling units 5-17

DDiagnostic display (DKC**.3-016) 5-14Dimensions 3-1Documentations 4-1dripping or sprayed water 5-17Drive address (DKC**.3-016) 5-15Drive enable 5-5Drive halt 5-5Drive halt (AH) and Drive enable (RF) (DKC**.3-016) 5-4

EEcoX expansion interface (DKC**.3-016) 5-12

HH1 (DKC**.3-016) 5-14Holding brake (DKC**.3-016) 5-10Holding brakes (DKC**.3-016) 5-8

IIdentification 2-1Important Notes 1-1Installation 5-15Instructions for use 5-1Insulation Monitoring (DKC**.3-016) 5-3

MMains connections

DKC**.3-016 5-8Mains Connections (DKC**.3-016) 5-6moisture condensation 5-18Motor connection (DKC**.3-016) 5-7Motor Connections (DKC**.3-016) 5-6

6-2 Index Rexroth EcoDrive 03 DKC**.3-016


Motor holding brake (DKC**.3-016) 5-11Motor power cables (DKC**.3-016) 5-7Motor temperature monitoring (DKC**.3-016) 5-8Motor temperature monitoring (TM+, TM) (DKC**.3-016) 5-9

OOvercurrent protection 5-1

PProtective conductor connections

XE1, XE2 5-13

RRatings 3-1Ready to operate contact

DKC**.3-016 5-5Reference documentations 4-1Resettaster (DKC**.3-016) 5-14

SS1 (DKC**.3-016) 5-14S2 (DKC**.3-016) 5-14S2, S3 (DKC**.3-016) 5-15S3 (DKC**.3-016) 5-14Safety Instructions 1-1Scope of supply 2-2Shield Connections (DKC**.3-016) 5-14

TTechnical description of connector

X10 5-12TM+, TM- (DKC**.3-016) 5-9Type code 2-1

DKC 2-1Type plates 2-1

UUse

appropriate 1-4

VVoltage connection for brakes (DKC**.3-016) 5-10

WWiring Diagram 5-1

XX1, Connections for Control voltage (DKC**.3-016) 5-3X10, EcoX Expansion interface (DKC**.3-016) 5-12X5, Motor and Mains Connections (DKC**.3-016) 5-6X6, Motor temperature monitoring (DKC**.3-016) 5-8XE1, XE2 5-13XS1 (DKC**.3-016) 5-14XS2 (DKC**.3-016) 5-14XS3 (DKC**.3-016) 5-14

Printed in Germany

Bosch Rexroth AGElectric Drives and ControlsP.O. Box 13 5797803 Lohr, GermanyBgm.-Dr.-Nebel-Str. 297816 Lohr, GermanyPhone +49 (0)93 52-40-50 60Fax +49 (0)93 52-40-49 [email protected]

dkc**.3-016 drive controllers

Documents