REXROTH EcoDrive 03 Instruction Manual
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REXROTH EcoDrive 03 Instruction Manual

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Electric Drives
and Controls
Hydraulics
Rexroth EcoDrive 03
Drive Controllers
DKC**.3-040, -100, -200
Instruction Manual
Linear Motion and
Assembly Technologies
Pneumatics
Service
R911320342
Edition 01

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Summary of Contents for REXROTH EcoDrive 03

  • Page 1 Electric Drives Linear Motion and and Controls Hydraulics Assembly Technologies Pneumatics Service Rexroth EcoDrive 03 R911320342 Edition 01 Drive Controllers DKC**.3-040, -100, -200 Instruction Manual...
  • Page 2 About this Documentation Rexroth EcoDrive 03 Rexroth EcoDrive 03 Title Drive Controllers DKC03.3-040, -100, -200 Instruction Manual Type of Documentation DOK-ECODR3-DKC40*200UL-IB01-EN-P Document Typecode 120-1000-B364-01/EN Internal File Reference This documentation provides information on the installation and operation Purpose of Documentation of the described products, by persons trained and qualified to work with electrical installations.

  • Page 3: Table Of Contents

    Rexroth EcoDrive 03 DKC**.3-040...200 Contents Contents Important Notes 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 Appropriate Use..........................1-4 Identification Type Code ............................
  • Page 4 Contents Rexroth EcoDrive 03 DKC**.3-040...200 Appendix Discharging of DC Bus Capacitors ....................6-1 Discharging Device........................6-2 Index DOK-ECODR3-DKC40*200UL-IB01-EN-P...

  • Page 5: Important Notes

    • If these documentations contain some information you do not understand, it is absolutely necessary that you ask Bosch Rexroth for explanation before you start working on or with the devices.

  • Page 6: Contact With Electrical Parts

    Important Notes Rexroth EcoDrive 03 DKC**.3-040...200 Contact with Electrical Parts 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 been...
  • Page 7 Rexroth EcoDrive 03 DKC**.3-040...200 Important Notes Dangerous movements can occur immediately after equipment is switched on or even after an unspecified time of trouble-free operation. The monitoring in the drive components will normally be sufficient to avoid faulty operation in the connected drives. Regarding personal safety, especially the danger of bodily harm and material damage, this alone cannot be relied upon to ensure complete safety.

  • Page 8: Magnetic And Electromagnetic Fields

    Important Notes Rexroth EcoDrive 03 DKC**.3-040...200 Magnetic and Electromagnetic Fields Health hazard for persons with heart pacemakers, metal implants and hearing aids in proximity to electrical equipment! • Persons with heart pacemakers and metal implants are not permitted to enter following...

  • Page 9: Identification

    Rexroth EcoDrive 03 DKC**.3-040...200 Identification Identification Type Code Note: The following figure illustrates the basic structure of the type code. Our sales representative will help you with the current status of available versions. DKC 03.3 - 040 - 7 - FW...

  • Page 10: Scope Of Supply

    Identification Rexroth EcoDrive 03 DKC**.3-040...200 Scope of Supply • firmware module • contact protection • connectors according to the following table: Type Connectors - type independent X.. Connectors - type dependent X.. DKC01.3-***-7 DKC02.3-***-7 DKC03.3-***-7 DKC04.3-***-7 DKC05.3-***-7 DKC06.3-***-7 DKC11.3-***-7 DKC21.3-***-7 DKC22.3-***-7...

  • Page 11: Ratings And Dimensions

    Rexroth EcoDrive 03 DKC**.3-040...200 Ratings and Dimensions Ratings and Dimensions Description Symbol Unit DKC03.3-040 DKC03.3-100 DKC03.3-200 listing according UL-standard (UL) UL 508 C listing according CSA-standard (UL) Canadian National Standard(s) C22.2 No. 14-05 UL files (UL) E134201 E134201 E134201 pollution degree (UL)
  • Page 12 Ratings and Dimensions Rexroth EcoDrive 03 DKC**.3-040...200 Description Symbol Unit DKC03.3-040 DKC03.3-100 DKC03.3-200 power dissipation at continuous current I out_cont and continuous DC bus power P DC_cont Diss_cont respectively (UL) 1) 2) 3) housing dimension; see related dimension sheet also 4) 5) see fig.

  • Page 13: Reference Documentations

    Rexroth EcoDrive 03 DKC**.3-040...200 Reference Documentations Reference Documentations Overview Title Type Document Typecode Servo Applications with 1,5 s Acceleration Selection lists DOK-ECODR3-SERV-GEN***-AUxx-MS-P Time Servo Applications with 400 ms Acceleration Selection lists DOK-ECODR3-SERV-WZM***-AUxx-MS-P Time Main drives with 2AD-, ADF and 1MB-motors...
  • Page 14 Reference Documentations Rexroth EcoDrive 03 DKC**.3-040...200 Title Type Document Typecode ECODRIVE03 Drive for Machine Tool Troubleshooting Guide DOK-ECODR3-SMT-02VRS**-WAR*-EN-P Applications With SERCOS-, Analog and Parallelinterface ECODRIVE03 Drive for General Automation Troubleshooting Guide DOK-ECODR3-SGP-01VRS**-WAxx-EN-P With SERCOS-, Analog and Parallel interface ECODRIVE03 Drive for General Automation...

  • Page 15: Instructions For Use

    Rexroth EcoDrive 03 DKC**.3-040...200 Instructions for Use Instructions for Use Overcurrent Protection Branch circuit protection has to be provided externally according to the maximum values (voltage and current or voltage and percent of FLA of the fuses [FLA: Full Load Ampacity]).

  • Page 16: Connection Diagram

    Instructions for Use Rexroth EcoDrive 03 DKC**.3-040...200 Connection Diagram Rexroth EcoDrive 03 (DKC**.040, DKC**.100, DKC**.200) Fig. 5-2: Total connection diagram for DKC**.3 DOK-ECODR3-DKC40*200UL-IB01-EN-P...

  • Page 17: X1, Connections For Control Voltage

    Rexroth EcoDrive 03 DKC**.3-040...200 Instructions for Use X1, Connections for Control voltage Technical description of connector Illustration: Ap5264f1.FH7 Fig. 5-3: Connector X1 Design: Type No. of pins Design Spring contact 2 x 4 Bushing on connector Fig. 5-4: Design Connection cross section:...
  • Page 18 Instructions for Use Rexroth EcoDrive 03 DKC**.3-040...200 Note: The input 0 V is connected directly to the device potential. The utilization of an insulation monitoring for +24 V and 0 V against device is therefore not possible! wire cross section: min.
  • Page 19 Rexroth EcoDrive 03 DKC**.3-040...200 Instructions for Use Input circuit AH and RF: Ap5183f1.fh7 Schematics no data Fig. 5-9: Input circuit Inputs Input voltage: min. max. AH and RF: High 16 V 30 V -0.5 V Input resistance 13.3 kOhm ±5%...

  • Page 20: Connection Of Control Interfaces And Terminals

    Instructions for Use Rexroth EcoDrive 03 DKC**.3-040...200 The Bb contacts opens: Switching states • if control voltage for DKC is not applied • if 24 volts not present at the emergency stop input when the E-stop function is activated (depends on parameterization, see function description).
  • Page 21 Rexroth EcoDrive 03 DKC**.3-040...200 Instructions for Use Design: Type No. of pins Design connection block 2 / 3 / 3 screw-in connection for ring terminals M5 Fig. 5-13: Design Tightening torque: min. tightening torque max. tightening torque [Nm] [Nm] Fig. 5-14: Tightening torque...
  • Page 22 Motor: motor connection AP5302F1.FH7 Fig. 5-17: Motor connections Use Rexroth motor power cables to connect motor and controller. Cable Motor: Note: For technical data on connections and cross sections, see the motor project planning manual. Cable length: Maximum length equals 75 m: •...

  • Page 23: X6, Motor Temperature Monitoring And Holding Brakes

    Rexroth EcoDrive 03 DKC**.3-040...200 Instructions for Use Mains connections The mains connector serves as the connection of the drive controller with the power supply. Single-phase mains connection: device-external device-internal n.c. AP5370F1.FH7 Fig. 5-19: Single-phase mains connection Three-phase mains connection: device-external...
  • Page 24 Motor temperature evaluation: Drive Controller MOTOR AP5326F1.FH7 Schematics approximately 5 V approximately 2 k Fig. 5-25: Motor temperature evaluation Note: Connections TM+ and TM- are only to be used with Rexroth motors. ⇒ See also firmware functional description : "Temperature monitoring". DOK-ECODR3-DKC40*200UL-IB01-EN-P...
  • Page 25 5-11 Rexroth EcoDrive 03 DKC**.3-040...200 Instructions for Use Holding brake (BR+, BR-) Dangerous movements! Danger to personnel from falling or dropping axes! ⇒ The standard equipment motor brake or an external brake controlled directly by the servo drive are not...
  • Page 26 5-12 Instructions for Use Rexroth EcoDrive 03 DKC**.3-040...200 Voltage connection for brakes Note: The motor holding brake is not supplied by the controller. Given one voltage source for brake and control voltage, use parallel leads from the voltage source. Insert the brake voltage supply cable in the touch guard from the bottom or from the side.
  • Page 27 5-13 Rexroth EcoDrive 03 DKC**.3-040...200 Instructions for Use Voltage connection for brakes max. voltage at X6.5/7 against X6.6/8: DC 40 V on DKC: current consumption at X6.5 and needed supply see "Technical data" brake voltage: in the motor manual max. allowed current load when looping through DC 10 A brake supply over X6.5/6 to X6.7/8:...

  • Page 28: X7, Connection For Programming Module

    5-14 Instructions for Use Rexroth EcoDrive 03 DKC**.3-040...200 A1 A2 A3 AC-Motor Holding Temperature brake dependent resistance AP5125F1.FH7 Fig. 5-30: Connection of motor cable, holding brake and temperature monitor for motors with connector box Note: The cable designations and all details on making cables are outlined in the cable or motor document.

  • Page 29: X12, Optional Choke Connection For Dkc**.3-200-7

    5-15 Rexroth EcoDrive 03 DKC**.3-040...200 Instructions for Use Setting the Drive Address Two decade switches are used to set the drive address. It can be set to Switch S2, S3; drive address: any number between 1 and 99. Example: Switch setting S3 = 9 (value of tens)

  • Page 30: Xe1, Xe2 Protective Conductor Connections For Motor And Mains

    5-16 Instructions for Use Rexroth EcoDrive 03 DKC**.3-040...200 Connection cross section: Cross section Cross section Cross section single wire multi core wire in AWG [mm²] [mm²] Gauge no.: 10 - 25 Fig. 5-36: Connection cross section Connection Choke (DR+, DR-)

  • Page 31: Xs1, Xs2, Xs3 Shield Connections

    5-17 Rexroth EcoDrive 03 DKC**.3-040...200 Instructions for Use Tightening torque: min. tightening torque max. tightening torque [Nm] [Nm] Fig. 5-39: Tightening torque Connection cross section: Cross section Max. connectable Max. cross section single wire cross section in AWG [mm²] in mm²...

  • Page 32: Installation

    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 in accordance with EN 50178. Risk of damage to the drive controller by connecting and disconnecting live connections! ⇒...

  • Page 33: Touch Guard At Devices

    5-19 Rexroth EcoDrive 03 DKC**.3-040...200 Instructions for Use Touch Guard at Devices Lethal electric shock caused by live parts with more than 50 V! • The appropriate touch guard must be mounted for each device following connection work. WARNING • Never mount a damaged touch guard.

  • Page 34: Sizing Of Enclosure And Control Cabinet

    5-20 Instructions for Use Rexroth EcoDrive 03 DKC**.3-040...200 Sizing of Enclosure and Control Cabinet Control Cabinet with Multiple-Line Structure Note: Particular attention should be paid to the maximum allowed air intake temperature of components when they are arranged in multiple lines in the control cabinet. Where necessary, cooling air guides are to be provided with blowers specially used for this purpose.
  • Page 35 5-21 Rexroth EcoDrive 03 DKC**.3-040...200 Instructions for Use correct incorrect Cooling system Cooling system warm cold warm cold Air duct electronic electronic equipment equipment Cabinet Cabinet Eb0001f1.fh7 Fig. 5-43: Arranging the cooling unit on the control cabinet incorrect correct control cabinet...
  • Page 36 5-22 Instructions for Use Rexroth EcoDrive 03 DKC**.3-040...200 • Only use well-sealed control cabinets so that moisture condensation cannot arise as a result of warm and moist external air entering the cabinet. In the event that control cabinets are operated with the doors open (commissioning, servicing etc.) it is essential to ensure that after the...

  • Page 37: Discharging Of Dc Bus Capacitors

    Appendix Appendix Discharging of DC Bus Capacitors In the drive system Rexroth IndraDrive capacitors are used in the DC bus as energy stores. In the drive controllers and particularly in the supply units such capacitors have already been integrated. Energy stores maintain their energy even when energy supply has been cut off and have to be discharged before somebody gets in contact with them.
  • Page 38 Appendix Rexroth EcoDrive 03 DKC**.3-040...200 Discharging Device Lethal electric shock caused by live parts with more than 50 V! Before touching live parts check in any case whether ⇒ the voltage between the DC bus terminals L+ and L- WARNING...
  • Page 39 Rexroth EcoDrive 03 DKC**.3-040...200 Index Index 24V control voltage supply (+24V and 0V) 5-3 Appendix 6-1 Appropriate use 1-4 Basic connection of holding brake 5-13 Basic connection of motor power 5-13 Basic connection of motor temperature monitoring 5-13 Bb 5-5...
  • Page 40 Index Rexroth EcoDrive 03 DKC**.3-040...200 Mains connections DKC 5-9 moisture condensation 5-21 Motor connection 5-8 Motor holding brake 5-13 Motor power cables 5-8 Motor temperature monitoring 5-9 Motor temperature monitoring (TM+, TM) 5-10 Optional Choke Connection for DKC**.3-200-7 5-15 Overcurrent Protection 5-1...
  • Page 41 Rexroth EcoDrive 03 DKC**.3-040...200 Index X1, Connections for Control voltage 5-3 X12, Optional Choke Connection for DKC**.3-200-7 5-15 X5, DC bus, Motor and Mains Connections 5-6 X6, Motor temperature monitoring 5-9 X7, Connection for Programming module 5-14 XE1, XE2 5-16...
  • Page 42 Index Rexroth EcoDrive 03 DKC**.3-040...200 DOK-ECODR3-DKC40*200UL-IB01-EN-P...
  • Page 44 Bosch Rexroth AG Electric Drives and Controls P.O. Box 13 57 97803 Lohr, Germany Bgm.-Dr.-Nebel-Str. 2 97816 Lohr, Germany Phone +49 (0)93 52-40-50 60 +49 (0)93 52-40-49 41 service.svc@boschrexroth.de www.boschrexroth.com Printed in Germany...

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