REXROTH EcoDrive Cs Technical manual

Rexroth IndraControl VCP 20
Industrial
Hydraulics
Electric Drives
and Controls
Linear Motion and
Assembly Technologies Pneumatics
Service
Automation
Mobile
Hydraulics
Rexroth EcoDrive Cs
Drives
R911295758
Edition 02
Project Planning Manual
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About this Documentation Rexroth EcoDrive Cs Drives
DOK-ECODR3-DKC**.3-CS*-PR02-EN-P
Rexroth EcoDrive Cs
Drives
Project Planning Manual
DOK-ECODR3-DKC**.3-CS*-PR02-EN-P
•Document Number 120-1000-B344-02
This documentation describes …
•planning the mechanical control cabinet construction
•planning the electrical control cabinet construction
•logistical handling of the equipment
Description Release
Date Notes
DOK-ECODR3-DKC**.3-CS*-PR01-EN-P 03.2004 first edition
DOK-ECODR3-DKC**.3-CS*-PR02-EN-P 11.2004 second edition
 Bosch Rexroth AG 2004
Copying this document, giving it to others and the use or communication
of the contents thereof without express authority, are forbidden. Offenders
are liable for the payment of damages. All rights are reserved in the event
of the grant of a patent or the registration of a utility model or design
(DIN 34-1).
The specified data only serve to describe the product. No statements
concerning a certain condition or suitability for a certain application can be
derived from our information. The given information does not release the
user from the obligation of own judgement and verification. It must be
remembered that our products are subject to a natural process of wear
and aging.
Bosch Rexroth AG
Bgm.-Dr.-Nebel-Str. 2 •D-97816 Lohr a. Main
Telephone [phone] •Tx 68 94 21 •Fax [phone]
http://www.boschrexroth.de/
Dept. EDY/EDY1 (MW/US)
This document has been printed on chlorine-free bleached paper.
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Rexroth EcoDrive Cs Drives Contents I
DOK-ECODR3-DKC**.3-CS*-PR02-EN-P
Contents
1 Introduction to the System 1-1
1.1 Rexroth EcoDrive Cs Drive System.............................................................................................. 1-1
1.2 Rexroth EcoDrive Cs Device Range ............................................................................................ 1-2
Individual Components............................................................................................................ 1-2
Configuration ........................................................................................................................... 1-2
1.3 Drive Controller – Motor Combinations ........................................................................................1-4
1.4 Type Codes .................................................................................................................................. 1-5
Drive Controllers with Analog/Parallel Interface...................................................................... 1-5
Drive Controllers with SERCOS interface ............................................................................... 1-6
Drive Controllers without Master Communication (Basic Devices)......................................... 1-7
Master Communication............................................................................................................1-8
2 Important Directions for Use 2-1
2.1 Appropriate Use............................................................................................................................ 2-1
Introduction.............................................................................................................................. 2-1
Areas of Use and Application.................................................................................................. 2-2
2.2 Inappropriate Use......................................................................................................................... 2-2
3 Safety Instructions for Electric Drives and Controls 3-1
3.1 Introduction................................................................................................................................... 3-1
3.2 Explanations ................................................................................................................................. 3-1
3.3 Hazards by Improper Use............................................................................................................. 3-2
3.4 General Information...................................................................................................................... 3-3
3.5 Protection Against Contact with Electrical Parts........................................................................... 3-5
3.6 Protection Against Electric Shock by Protective Low Voltage (PELV)......................................... 3-6
3.7 Protection Against Dangerous Movements.................................................................................. 3-7
3.8 Protection Against Magnetic and Electromagnetic Fields During Operation and
Mounting....................................................................................................................................... 3-9
3.9 Protection Against Contact with Hot Parts.................................................................................. 3-10
3.10 Protection During Handling and Mounting.................................................................................. 3-10
3.11 Battery Safety............................................................................................................................. 3-11
3.12 Protection Against Pressurized Systems.................................................................................... 3-11
4 Technical Data (Drive Controllers) 4-1
4.1 Dimensional Drawings.................................................................................................................. 4-1
DKC01.3-0xx Drive Controllers with Analog/Parallel Interface ............................................... 4-1
DKC02.3-004 (100 W), DKC02.3-008 (200 W) and DKC02.3-012 (400 W) Drive
Controllers with SERCOS interface......................................................................................... 4-2
DKC02.3-018 (750 W) Drive Controller with SERCOS interface............................................ 4-3
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II Contents Rexroth EcoDrive Cs Drives
DOK-ECODR3-DKC**.3-CS*-PR02-EN-P
DKC10.3-004 (100 W), DKC10.3-008 (200 W) and DKC10.3-012 (400 W) Drive
Controllers – Basic Devices.....................................................................................................4-4
DKC10.3-018 (750 W) Drive Controller – Basic Device.......................................................... 4-5
4.2 Mass and Materials....................................................................................................................... 4-6
4.3 Ambient and Operating Conditions............................................................................................... 4-7
4.4 Electrical Data............................................................................................................................... 4-9
Power Section.......................................................................................................................... 4-9
Performance Data.................................................................................................................. 4-11
Control Voltage Connection................................................................................................... 4-15
4.5 Control and Display Elements (H1, S1, S2, S3)......................................................................... 4-16
H1 (Diagnostic Display).........................................................................................................4-16
S1 (Button)............................................................................................................................. 4-16
S2, S3 (Address Switch)........................................................................................................ 4-16
4.6 CE Label, C-UL Listing, Tests .................................................................................................... 4-17
5 Electrical Connections 5-1
5.1 Connections Independent of the Device....................................................................................... 5-1
Views of the Devices and Terminal Connector Designations ................................................. 5-1
Schematic Overall Connection Diagram ................................................................................. 5-3
X1, Mains and Control Voltage................................................................................................ 5-5
X2, Additional Choke and Braking Resistor ............................................................................ 5-6
X3, Motor................................................................................................................................. 5-9
Ground Connection ...............................................................................................................5-11
X4, Encoder........................................................................................................................... 5-12
X5_1: Digital Inputs ............................................................................................................... 5-13
X5_2: Digital Outputs............................................................................................................. 5-15
X5_3: Holding Brake.............................................................................................................. 5-18
X6, Serial Interface RS232.................................................................................................... 5-21
5.2 Connections Dependent on the Device...................................................................................... 5-23
DKC01.3 – Analog/Parallel Interface..................................................................................... 5-23
DKC02.3 – SERCOS interface.............................................................................................. 5-31
DKC03.3 – Profibus-DP Interface.......................................................................................... 5-33
DKC06.3 – DeviceNet Interface with COMBICON Connector.............................................. 5-39
DKC16.3 – DeviceNet Interface with Sealed Micro-Style Connector.................................... 5-41
DKC05.3 – CANopen Interface ............................................................................................. 5-43
5.3 Mounting a Master Communication Module............................................................................... 5-45
Removing the Shipping Brace............................................................................................... 5-45
Inserting the Master Communication Module........................................................................ 5-46
5.4 Replacing a Master Communication Module.............................................................................. 5-47
6 Mains and Supply Voltage Connection 6-1
6.1 Connection Features .................................................................................................................... 6-2
6.2 Kinds of Connection...................................................................................................................... 6-3
Single-Phase Connection........................................................................................................ 6-3
Three-Phase Connection......................................................................................................... 6-4
6.3 Inrush Current and Mains Phase Current..................................................................................... 6-5
Characteristic of Inrush Current............................................................................................... 6-5
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Rexroth EcoDrive Cs Drives Contents III
DOK-ECODR3-DKC**.3-CS*-PR02-EN-P
Inrush Current Impulse............................................................................................................ 6-6
Computing Phase Current on the Mains ................................................................................. 6-9
Mains Connection with Phase Currents of More than 25 A................................................... 6-11
Mains Connection with Phase Currents of Less than 25 A................................................... 6-12
6.4 Selecting Q1 Fuse and K1 Contactor......................................................................................... 6-13
6.5 Mains Filter ................................................................................................................................. 6-14
6.6 Operation on 400/480 V Mains................................................................................................... 6-15
Basics.................................................................................................................................... 6-15
Selecting the Mains Transformer .......................................................................................... 6-15
6.7 The Ground Conditions of the Power Supply Network............................................................... 6-16
6.8 Earth-leakage Circuit Breaker .................................................................................................... 6-17
6.9 Control Circuits for the Mains Connection.................................................................................. 6-17
Overview................................................................................................................................ 6-17
Control Circuits with E-Stop................................................................................................... 6-18
7 Designing the Control Cabinet 7-1
7.1 Notes on Control Cabinet Project Planning.................................................................................. 7-1
Mounting Position and Distances............................................................................................ 7-1
Arranging the Components in the Control Cabinet.................................................................. 7-3
7.2 Using Cooling Units in the Control Cabinet.................................................................................. 7-4
7.3 General Information...................................................................................................................... 7-6
7.4 Wire Routing in the Control Cabinet............................................................................................. 7-7
7.5 EMC in the Control Cabinet.......................................................................................................... 7-7
8 Motors 8-1
8.1 Overview....................................................................................................................................... 8-1
Basic Type............................................................................................................................... 8-1
Options .................................................................................................................................... 8-1
Benefits.................................................................................................................................... 8-1
8.2 MSM Type Code........................................................................................................................... 8-2
Motor MSM020B...................................................................................................................... 8-2
Motor MSM030........................................................................................................................ 8-3
Motor MSM040B...................................................................................................................... 8-4
Types....................................................................................................................................... 8-5
8.3 Technical Data.............................................................................................................................. 8-6
Basics...................................................................................................................................... 8-6
Definition of Parameters.......................................................................................................... 8-7
8.4 MSM020B..................................................................................................................................... 8-9
Dimensions.............................................................................................................................. 8-9
Key......................................................................................................................................... 8-10
Cables at the Motor ............................................................................................................... 8-10
Technical Data....................................................................................................................... 8-11
8.5 MSM030B................................................................................................................................... 8-13
Dimensions............................................................................................................................ 8-13
Key......................................................................................................................................... 8-14
Cables at the Motor ............................................................................................................... 8-14
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IV Contents Rexroth EcoDrive Cs Drives
DOK-ECODR3-DKC**.3-CS*-PR02-EN-P
Technical Data....................................................................................................................... 8-15
8.6 MSM030C................................................................................................................................... 8-17
Dimensions............................................................................................................................ 8-17
Key......................................................................................................................................... 8-18
Cables at the Motor ............................................................................................................... 8-18
Technical Data....................................................................................................................... 8-19
8.7 MSM040B................................................................................................................................... 8-21
Dimensions............................................................................................................................ 8-21
Key......................................................................................................................................... 8-22
Cables at the Motor ............................................................................................................... 8-22
Technical Data....................................................................................................................... 8-23
8.8 Application Instructions............................................................................................................... 8-25
Operating Conditions............................................................................................................. 8-25
Degree of protection.............................................................................................................. 8-26
Design and Installation Positions........................................................................................... 8-27
Housing Materials.................................................................................................................. 8-28
Holding Brake........................................................................................................................ 8-29
Output Shaft and Motor Bearing............................................................................................ 8-30
Encoder ................................................................................................................................. 8-34
Acceptances, Approvals........................................................................................................ 8-39
8.9 Assembly.................................................................................................................................... 8-40
Skilled Technical Personnel .................................................................................................. 8-40
Mounting the Motor................................................................................................................ 8-40
Connecting the Motor ............................................................................................................8-41
8.10 Startup, Operation, and Maintenance.........................................................................................8-42
Startup................................................................................................................................... 8-42
Operation............................................................................................................................... 8-43
Maintenance.......................................................................................................................... 8-43
9 Identifying the Components 9-1
9.1 Marking the Components.............................................................................................................. 9-1
9.2 Type Plates................................................................................................................................... 9-1
Type Plates at the Drive Controller.......................................................................................... 9-1
Type Plate at the Motor........................................................................................................... 9-3
10 Additional Components 10-1
10.1 Cables......................................................................................................................................... 10-1
Motor Cable IKG0331............................................................................................................ 10-1
Motor Extension Cable IKG0332........................................................................................... 10-2
Encoder Cable IKS0230........................................................................................................ 10-3
Encoder Extension Cable IKS0232....................................................................................... 10-4
Encoder Emulation Cable RKG0008..................................................................................... 10-5
RS232 Cable IKB0041 .......................................................................................................... 10-6
10.2 Accessories ................................................................................................................................ 10-7
SUP-E01-DKC*CS-CONSIG................................................................................................. 10-7
SUP-E02-DKC*CS-CONPWR............................................................................................. 10-10
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Rexroth EcoDrive Cs Drives Contents V
DOK-ECODR3-DKC**.3-CS*-PR02-EN-P
SUP-E03-DKC*CS-BATTRY............................................................................................... 10-12
SUP-E04-DKC*CS-ENCODR (Encoder Adapter)............................................................... 10-13
SUP-E05-DKC*CS-SURGEP.............................................................................................. 10-19
SUP-E06-DKC*CS-CONSIG............................................................................................... 10-21
10.3 Braking Resistor ....................................................................................................................... 10-23
Notes ................................................................................................................................... 10-23
Identification......................................................................................................................... 10-23
Mechanical Data.................................................................................................................. 10-24
Electrical Data...................................................................................................................... 10-25
10.4 DC24V NTM power supplies .................................................................................................... 10-26
Application recommendations ............................................................................................. 10-26
Technical data ..................................................................................................................... 10-26
Dimensional sheets and installation dimensions................................................................. 10-27
Front views .......................................................................................................................... 10-27
Electrical connection............................................................................................................ 10-28
Type code............................................................................................................................ 10-29
10.5 DST transformers ..................................................................................................................... 10-30
Selection.............................................................................................................................. 10-30
Autotransformers for Drive Controllers................................................................................ 10-30
Technical Data..................................................................................................................... 10-31
Type Code........................................................................................................................... 10-37
10.6 Mains Filter ............................................................................................................................... 10-38
NFE01.1............................................................................................................................... 10-38
NFE02.1............................................................................................................................... 10-39
NFD03.1 .............................................................................................................................. 10-40
11 Service & Support 11-1
11.1 Helpdesk..................................................................................................................................... 11-1
11.2 Service-Hotline ........................................................................................................................... 11-1
11.3 Internet........................................................................................................................................ 11-1
11.4 Vor der Kontaktaufnahme... - Before contacting us... ................................................................ 11-1
11.5 Kundenbetreuungsstellen - Sales & Service Facilities............................................................... 11-2
12 Index 12-1
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VI Contents Rexroth EcoDrive Cs Drives
DOK-ECODR3-DKC**.3-CS*-PR02-EN-P
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Rexroth EcoDrive Cs Drives Introduction to the System 1-1
DOK-ECODR3-DKC**.3-CS*-PR02-EN-P
1 Introduction to the System
1.1 Rexroth EcoDrive Cs Drive System
Rexroth EcoDrive Cs is a new generation of system-compatible AC servo
drives in the lower power range of 100 to 750 W. The drive controllers
and motors have a specifically compact design.
The drive controllers are equipped with the SERCOS interface,
PROFIBUS-DP, DeviceNet or CANopen master communication modules;
they are perfectly suited for use in systems with multiple-axis devices and
can also be used as intelligent single axes on a standard field bus.
There are four motor sizes (100 W, 200 W, 400 W, 750 W) with minimum
dimensions that are adapted to the drive controllers.
The following options are available for the motors:
•integrated holding brake
•drive shaft with key
•absolute encoder for detecting the current position of the load without
travelling to reference point
Typical applications of Rexroth EcoDrive Cs are:
•handling systems
•packaging machines
•mounting systems
•printing machines
•machine tools
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1-2 Introduction to the System Rexroth EcoDrive Cs Drives
DOK-ECODR3-DKC**.3-CS*-PR02-EN-P
1.2 Rexroth EcoDrive Cs Device Range
Individual Components
The following individual components are available for Rexroth
EcoDrive Cs:
•motors
•basic devices
•master communication cards
•battery for the absolute encoder
•cables (motor, encoder, RS232)
•connection and mounting accessories
•external braking resistor
•mains transformer
Note: These individual components can be ordered individually.
Configuration
A drive controller with PROFIBUS-DP, DeviceNet or CANopen interface is
characterized by the configuration of the basic device with the respective
master communication card.
There are the following end devices:
End device Basic device Master
communication
card
Master
communication
DKC01.3-0xx - none analog/parallel
DKC02.3-0xx - none SERCOS
DKC03.3-0xx DKC10.3-0xx ECM01.1-PB01 PROFIBUS-DP
DKC05.3-0xx DKC10.3-0xx ECM01.1-CN01 CANopen
DKC06.3-0xx DKC10.3-0xx ECM01.1-DN01 DeviceNet
DKC10.3-0xx DKC10.3-0xx ECM01.1-NNNN digital I/Os
DKC16.3-0xx DKC10.3-0xx ECM01.1-DN02 DeviceNet with
sealed micro-style
connector
Fig. 1-1: Device configurations for Rexroth EcoDrive Cs
Note: Mounting a master communication card: see chapter 5.3.
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