ctrlX DRIVE - Bosch Rexroth

ctrlX DRIVE

Drive Controllers, Supply Units

Instruction ManualR911392530

Edition 02

ctrlX DRIVEDrive Controllers, Supply Units

Instruction Manual

DOK-XDRV**-X*****UL***-IN02-EN-P

RS-7f6c9a51f782d20fc0a802862510a79d-2-en-US-2

Purpose of Documentation This documentation provides information on the installation and operation ofthe described products, by persons trained and qualified to work with electri‐cal installations.

Copyright © Bosch Rexroth AG 2021All rights reserved, also regarding any disposal, exploitation, reproduction,editing, distribution, as well as in the event of applications for industrial prop‐erty rights.

Liability The specified data is intended for product description purposes only and shallnot be deemed to be a guaranteed characteristic unless expressly stipulatedin the contract. All rights are reserved with respect to the content of this docu‐mentation and the availability of the product.

Title

Type of Documentation

Document Typecode

Internal File Reference

ctrlX DRIVE Drive Controllers, Supply Units

Table of ContentsPage

1 Important notes.............................................................................................................. 11.1 Safety instructions.................................................................................................................................. 11.1.1 General information............................................................................................................................. 11.1.2 Protection against contact with electrical parts and housings............................................................. 21.1.3 Battery safety....................................................................................................................................... 31.2 Intended use........................................................................................................................................... 4

2 Ratings and dimensions................................................................................................. 52.1 Ambient and operating conditions.......................................................................................................... 52.2 Drive controllers...................................................................................................................................... 82.3 Supply units.......................................................................................................................................... 172.4 China RoHS 2....................................................................................................................................... 19

3 Overview of documentations........................................................................................ 213.1 Motors................................................................................................................................................... 21

4 Instructions for use....................................................................................................... 234.1 Overcurrent protection.......................................................................................................................... 234.2 Connection............................................................................................................................................ 234.2.1 General information........................................................................................................................... 234.2.2 Overall connection diagram XCS*-W0054…W0070......................................................................... 244.2.3 Overall connection diagram XCS*-W01xx......................................................................................... 254.2.4 Overall connection diagram XCS*-W02xx......................................................................................... 264.2.5 Overall connection diagram XCD...................................................................................................... 274.2.6 Overall connection diagram XMS*-W0006…W0036......................................................................... 284.2.7 Overall connection diagram XMS*-W0054…W0090......................................................................... 294.2.8 Overall connection diagram XMS*-W0100…W0280......................................................................... 304.2.9 Overall connection diagram XMD*-W0606…W2323......................................................................... 314.2.10 Overall connection diagram XMD*-W5454…W7070......................................................................... 324.2.11 Overall connection diagram XMQ*-WQ001....................................................................................... 334.2.12 Overall connection diagram XMQ*-WQ002....................................................................................... 344.2.13 Overall connection diagram XVR...................................................................................................... 354.2.14 Symbols (connection diagram).......................................................................................................... 364.2.15 Connection points.............................................................................................................................. 37

5 Service and support..................................................................................................... 39

Index............................................................................................................................ 41

ctrlX DRIVE Drive Controllers, Supply Units I

Table of Contents

R911392530_Edition 02 Bosch Rexroth AG

II ctrlX DRIVE Drive Controllers, Supply Units

Bosch Rexroth AG R911392530_Edition 02

1 Important notes1.1 Safety instructions1.1.1 General information

● Do not attempt to install and operate the components of the electricdrive and control system without first reading all documentation providedwith the product. Read and understand these safety instructions and alluser documentation prior to working with these components. If you donot have the user documentation for the components, contact ourRexroth sales representative. Ask for these documents to be sent imme‐diately to the person or persons responsible for the safe operation of thecomponents.

● If the supplied documents contain some information you do not under‐stand, it is absolutely necessary that you ask Rexroth for explanationbefore you start working at or with the components.

● If the component is resold, rented and/or passed on to others in any oth‐er form, these safety instructions must be delivered with the componentin the official language of the user's country.

● Only qualified persons may work with components of the electric driveand control system or within its proximity.In terms of this Instruction Manual, qualified persons are those personswho are familiar with the installation, mounting, commissioning and op‐eration of the components of the electric drive and control system, aswell as with the hazards this implies, and who possess the qualificationstheir work requires. To comply with these qualifications, it is necessary,among other things,– to be trained, instructed or authorized to switch electric circuits and

components safely on and off, to ground them and to mark them,– to be trained or instructed to maintain and use adequate safety

equipment,– to attend a course of instruction in first aid.

● The technical data, connection and installation conditions of the compo‐nents are specified in the respective application documentations andmust be followed at all times.

● If the components 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 components or alter source co‐des.

● Do not mount damaged or faulty components or use them in operation.● Only use accessories and spare parts approved by Rexroth.● Follow the safety regulations and requirements of the country in which

the electric components of the electric drive and control system are op‐erated.

● Proper and correct transport, storage, mounting and installation, as wellas care in operation and maintenance, are prerequisites for optimal andsafe operation of the component.

Improper use of these components, failure to follow the safety instructions inthis document or tampering with the product, including disabling of safety de‐vices, could result in property damage, injury, electric shock or even death.

ctrlX DRIVE Drive Controllers, Supply Units 1/43

Important notes


1.1.2 Protection against contact with electrical parts and housings

This section concerns components of the electric drive and con‐trol system with voltages of more than 50 volts.

Contact with parts conducting voltages above 50 volts can cause personaldanger and electric shock. When operating components of the electric driveand control system, it is unavoidable that some parts of these componentsconduct dangerous voltage. High electrical voltage! Danger to life, risk of injury by electric shock or seri‐ous injury!● Only qualified persons are allowed to operate, maintain and/or repair the

components of the electric drive and control system.● Follow the general installation and safety regulations when working on

power installations.● Before switching on, the equipment grounding conductor must have

been permanently connected to all electric components in accordancewith the connection diagram.

● Even for brief measurements or tests, operation is only allowed if theequipment grounding conductor has been permanently connected to thepoints of the components provided for this purpose.

● Before accessing electrical parts with voltage potentials higher than50 V, you must disconnect electric components from the mains or fromthe power supply unit. Secure the electric component from reconnec‐tion.

● With electric components, observe the following aspects:Always wait 30 minutes after switching off power to allow live capacitorsto discharge before accessing an electric component. Measure the elec‐trical voltage of live parts before beginning to work to make sure that theequipment is safe to touch.

● Install the covers and guards provided for this purpose before switchingon.

● Never touch any electrical connection points of the components whilepower is turned on.

● Do not remove or plug in connectors when the component has beenpowered.

● Under specific conditions, electric drive systems can be operated atmains protected by residual-current-operated circuit-breakers sensitiveto universal current (RCDs/RCMs).

● Secure built-in devices from penetrating foreign objects and water, aswell as from direct contact, by providing an external housing, for exam‐ple a control cabinet.

High housing voltage and high leakage current! Danger to life, risk of injuryby electric shock!● Before switching on and before commissioning, ground or connect the

components of the electric drive and control system to the equipmentgrounding conductor at the grounding points.

2/43

Important notes



● Connect the equipment grounding conductor of the components of theelectric drive and control system permanently to the main power supplyat all times. The leakage current is greater than 3.5 mA.

● Establish an equipment grounding connection with a minimum crosssection according to the table below. With an outer conductor cross sec‐tion smaller than 10 mm2 (8 AWG), the alternative connection of twoequipment grounding conductors is allowed, each having the samecross section as the outer conductors.

Cross section outer con‐ductor

Minimum cross section equipment grounding conductorLeakage current ≥ 3.5 mA

1 equipment groundingconductor

2 equipment groundingconductors

1.5 mm2 (16 AWG)

10 mm2 (8 AWG)

2 × 1.5 mm2 (16 AWG)

2.5 mm2 (14 AWG) 2 × 2.5 mm2 (14 AWG)

4 mm2 (12 AWG) 2 × 4 mm2 (12 AWG)

6 mm2 (10 AWG) 2 × 6 mm2 (10 AWG)

10 mm2 (8 AWG) -

16 mm2 (6 AWG)

16 mm2 (6 AWG)

-

25 mm2 (4 AWG) -

35 mm2 (2 AWG) -

50 mm2 (1/0 AWG) 25 mm2 (4 AWG) -

70 mm2 (2/0 AWG) 35 mm2 (2 AWG) -

... ... ...

Tab. 1-1: Minimum cross section of the equipment grounding connection

1.1.3 Battery safetyBatteries consist of active chemicals in a solid housing. Therefore, improperhandling can cause injury or property damage.Risk of injury by improper handling!● Do not attempt to reactivate low batteries by heating or other methods

(risk of explosion and cauterization).● Do not attempt to recharge the batteries as this may cause leakage or

explosion.● Do not throw batteries into open flames.● Do not dismantle batteries.● When replacing the battery/batteries, do not damage the electrical parts

installed in the devices.● Only use the battery types specified for the product.


Important notes


Environmental protection and disposal! The batteries contained inthe product are considered dangerous goods during land, air, andsea transport (risk of explosion) in the sense of the legal regula‐tions. Dispose of used batteries separately from other waste. Ob‐serve the national regulations of your country.

1.2 Intended useThis product may only be used for the mentioned applications under thespecified application, ambient and operating conditions.This product is exclusively intended for use in machines and systems in anindustrial environment. This is to be understood as applications according toIEC 60204-1 "Safety of machinery, Electric equipment of machines" andNFPA 79 "Electrical Standard for Industrial Machinery".

Components of the ctrlX DRIVE system are products of Catego‐ry C3 (with restricted distribution) in accordance withIEC 61800‑3. This Category comprises EMC limit values for line-based and radiated noise emission. Compliance with this Catego‐ry (limit values) requires the appropriate measures of interferencesuppression to be used in the drive system (e.g., mains filters,shielding measures).These components are not provided for use in a public low-volt‐age mains supplying residential areas. If these components areused in such a mains, high-frequency interference is to be expec‐ted. This can require additional measures of interference suppres‐sion.

4/43

Important notes



2 Ratings and dimensions2.1 Ambient and operating conditions

Lethal electric shock by live parts with morethan 50 V!

WARNING

Only operate the device● with the connectors plugged on (even if no lines have been connected

to the connectors) and● with the equipment grounding conductor connected!

Control cabinet The devices in the ctrlX DRIVE product range, as well as their additionalcomponents (except for some braking resistors), have to be mounted in con‐trol cabinets.Check that the ambient and operating conditions, in particular the controlcabinet temperature, are complied with by calculating the heat levels in thecontrol cabinet. Afterwards, make the corresponding measurements to con‐firm that ambient and operating conditions have actually been observed. Inthe technical data of the individual components, the power dissipation isspecified as an important input value for calculating the heat levels.Ambient and operating conditions

Description Symbol Unit Value

Conductive dirt contamination Not allowed(Conductive dirt contamination can be prevented, forexample, by mounting the devices in control cabinetsof the degree of protection IP54 in accordance with

IEC529.)

Degree of protection (IEC529) IP20 2)

Use within scope of CSA / UL For use in NFPA 79 Applications only!

Installation altitude hnenn m 1000

Ambient temperature range Ta_work °C 0 … 40

Derating vs. ambient temperature:The performance data are reduced by the fac‐tor FTa in the ambient temperature rangeTa_work_red:

FTA = 1 - [(Ta - 40) × fTa]

Example: With an ambient temperatureTa = 50 °C and a capacity utilization factorfTa = 2%, the rated power is reduced to

PDC_cont_red = PDC_cont × FTa =

PDC_cont x (1 - [(50 - 40) x 0.02]) = PDC_cont x 0.8

Operation at ambient temperatures outside ofTa_work and Ta_work_red is not allowed!

Ta_work_red °C 40 … 55

fTa %/K 2


Ratings and dimensions


Description Symbol Unit Value

Derating vs. installation altitude:At an installation altitude h > hnenn, the availa‐ble performance data are reduced by the fac‐tor f1).At an installation altitude in the rangehmax_ohne to hmax, voltage-limiting measures(overvoltage limiters) have to be installed atthe mains connection of the drive system.Use above hmax is not allowed! hmax_ohne m 2000

hmax m 4000

Simultaneous derating for ambient tempera‐ture [°C] and installation altitude [m]

Allowed;reduce performance data with the product f × FTa

Derating factors (for fTa = 2 %/K)

[°C] [m]

1000 2000 4000

25 1 1 0.82

30 1 0.96 0.76

35 1 0.88 0.69

40 1 0.8 0.62

45 0.9 0.72 0.57

50 0.8 0.64 0.5

55 0.7 0.56 0.44

Relative humidity % 5 … 95

Absolute humidity g/m3 1 … 29

Moisture condensation Not allowed

Climatic category (IEC 60721‑3‑3) 3K3

Allowed pollution degree (IEC 60664‑1) 2

Resistance to chemically active substances(IEC 60721‑3‑3)

Class 3C1 3)

Vibration sine: amplitude (peak-peak) at10 … 57 Hz

mm 0.15

Vibration sine: acceleration at 57 … 150 Hz g 1

Overvoltage category III (according to IEC60664-1)

1) Reduced performance data for drive controllers: allowed DCbus continuous power, braking resistor continuous power, con‐tinuous current; additionally for converters: allowed mains volt‐age

2) Prerequisite for IP20: connector plugged in at the device, allphases connected and touch guard of DC bus connectionavailable at the device; without connector at the device, phasesnot connected (e.g., 1-phase mains connection) or withouttouch guard of DC bus connection at the device: IP10

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3) Resistance to hydrogen sulfide H2S tested according to ANSI/ISA‑71.04 (Class G3) for 10 years

Tab. 2-1: Ambient and operating conditions




2.2 Drive controllersUL ratings and dimensions (XCS)

Description Symbol Unit XCS*-W0054

XCS*-W0070

XCS*-W0100

XCS*-W0120

XCS*-W0150

XCS*-W0180

XCS*-W0210

XCS*-W0250

XCS*-W0280

Listing in accordance withUL standard UL 61800-5-1

Listing in accordance withCSA standard C22.2 No. 274-17

UL‑Files E134201 E328841 E134201

Pollution degree 2

Ambient temperaturerange with nominal data Tamax °C 40

Mass m kg 5.8 10.3 17 27

Device height1) H mm 309 340.5

Device depth2) T mm 196.5

Device width3) B mm 100 225 350

Minimum distance on thetop of the device4) dtop mm 80

Minimum distance on thebottom of the device5) dbot mm 80

Horizontal spacing at thedevice6) dhor mm

0 (for devices of the ctrlX DRIVE product group in the DC bus group (central supply))1.5 (for devices of the ctrlX DRIVE product group outside of the DC bus group (individualsupply))10 (for everything else (control cabinet wall, other devices, etc.))

Rated control voltage in‐put7) UN3 V 24

Rated control current in‐put8) IN3 A 5.6 4.6 4 6.9

Short circuit current rating SCCR A rms 42000

Rated input voltage, pow‐er9) ULN_nenn V AC 200Y/115V … 500Y/289V

Mains frequency fLN Hz 50 … 60

Rated input current ILN A AC 26.6 AC 34.5 AC 78 AC 101 AC 115 AC 148 AC 160 AC 176

Branch circuit protectionfuse10)

35 AClass J

50 AClass J 100 A class J 150 A Class J 250 A Class J

Required wire size in ac‐cordance with UL 508 A(internal wiring);11)

ALN AWG 8 3 1/0 kcmil 250

Field wiring material (ma‐terial; conductor tempera‐ture; class)

Cu; 75 °C; 1

Output voltage Uout VAC 0 … 500

DC 280 … 710

Output current Iout AAC 27

DC 29.4AC 35

DC 38.2AC 67DC 87

AC 71DC 87

AC 100DC 118

AC 120DC 133

AC 140DC 163

AC 147DC 176

AC 165DC 195

Maximum allowed DC buspower (ULN AC 400V) Pout kW 31.8 41.2 67.5 90 88.3 106 167 192 210

Output frequency range12) fout Hz 0 … 1600

1) 2) 3) Housing dimensions4) 5) 6) See fig. "Air intake and air outlet at device"7) Comply with supply voltage for motor holding brake;

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The following power supply unit has to be used in the scope ofCSA/UL: ● UL508-certified ● output voltage: DC 24V ● outputcurrent: ≤ 31 A; for power supply units with output current >31 A: install fuses in accordance with UL248

8) See information on "Rated power consumption control voltageinput at UN3"

9) Mains input L1, L2, L3; For use on a solidly grounded wyesource only.

10) Use cUL-listed fuses. Suitable for use on a circuit capable ofdelivering not more than 42000 rms symmetrical amperes,500 Volts maximum. If using inverse-time circuit breakers (inthis case, you are obligated to prove opposite UL that an ap‐propriate circuit breaker was used) or type E combination mo‐tor controllers instead of recommended fuses, see UL61800-5-1, section 5.2.3.6.2DV.4.1.3.

11) Copper wire; PVC-insulation (conductor temperature 75 °C;Ta ≤ 40 °C) in accordance with NFPA 79 chapter 12 andUL 508A chapter 28

12) Depending on switching frequency which was set in parameterP‑0‑0001

Tab. 2-2: UL ratings and dimensionsUL ratings and dimensions (XCD)

Description Symbol Unit XCD*-W2323

Listing in accordance with ULstandard UL 61800-5-1

Listing in accordance with CSAstandard C22.2 No. 274-17

UL‑Files E134201

Pollution degree 2

Ambient temperature range withnominal data Tamax °C 40

Mass m kg 5.7

Device height1) H mm 309


Device width3) B mm 100

Minimum distance on the top ofthe device4) dtop mm 80

Minimum distance on the bottomof the device5) dbot mm 80

Horizontal spacing at the device6) dhor mm

0 (for devices of the ctrlX DRIVE product group in the DC busgroup (central supply))1.5 (for devices of the ctrlX DRIVE product group outside of theDC bus group (individual supply))10 (for everything else (control cabinet wall, other devices, etc.))

Rated control voltage input7) UN3 V 24

Rated control current input8) IN3 A 6.6




Description Symbol Unit XCD*-W2323


Rated input voltage, power9) ULN_nenn V AC 200Y/115V … 500Y/289V


Rated input current ILN A 26.6

Branch circuit protection fuse10) 35 A Class J

Required wire size in accordancewith UL 508 A (internal wiring);11) ALN AWG 8

Field wiring material (material;conductor temperature; class) Cu; 75 °C; 1

Output voltage Uout VAC 0 … 500

DC 280 … 710

Output current Iout A2 × AC 7.7DC 29.4

Maximum allowed DC bus power(ULN AC 400V) Pout kW 31.8









Tab. 2-3: UL ratings and dimensions

10/43




UL ratings and dimensions (XMS*-W0006 … 0036)

Description Symbol Unit XMS*-W0006

XMS*-W0010

XMS*-W0016

XMS*-W0023

XMS*-W0030

XMS*-W0036



UL‑Files E134201

Pollution degree 2


Mass m kg 2.8



Device width3) B mm 50






Rated control current input8) IN3 A 3.3


Rated input voltage, power9) ULN_nom V DC 254 ... 750

Rated input current ILN A DC 2.4 DC 4.1 DC 6.5 DC 9.4 DC 14.6 DC 22


Output voltage Uout V AC 0 … 500

Output current Iout A AC 2 AC 3.3 AC 5.3 AC 7.7 AC 12 AC 18

Output frequency range11) fout Hz 0 ... 1600










Tab. 2-4: UL ratings and dimensionsUL ratings and dimensions (XMS*-W0054 … 0280)


XMS*-W0070

XMS*-W0090

XMS*-W0100

XMS*-W0120

XMS*-W0210

XMS*-W0250

XMS*-W0280



UL‑Files E134201

Pollution degree 2

Ambient temperature rangewith nominal data Tamax °C 40

Mass m kg 4.25 6.2 18.9





Minimum distance on the bot‐tom of the device5) dbot mm 80

Horizontal spacing at the de‐vice6) dhor mm

0 (for devices of the ctrlX DRIVE product group in the DC bus group(central supply))1.5 (for devices of the ctrlX DRIVE product group outside of the DCbus group (individual supply))10 (for everything else (control cabinet wall, other devices, etc.))


Rated control current input8) IN3 A 4.3 6.4



Rated input current ILN A DC29.4

DC38.2

DC49.1 DC 73 DC 77 DC

153DC161

DC180

Field wiring material (material;conductor temperature; class) Cu; 60/75 °C; 1

Output voltage Uout V AC 0 … 500

12/43





XMS*-W0070

XMS*-W0090

XMS*-W0100

XMS*-W0120

XMS*-W0210

XMS*-W0250

XMS*-W0280

Output current Iout A AC 27 AC 35 AC 45 AC 67 AC 71 AC140

AC147

AC165








Tab. 2-5: UL ratings and dimensionsUL ratings and dimensions (XMD*)

Description Symbol Unit XMD*-W0606

XMD*-W1010

XMD*-W1616

XMD*-W2323

XMD*-W5454

XMD*-W7070



UL‑Files E134201

Pollution degree 2


Mass m kg 3.3 6.7



Device width3) B mm 50 150








Description Symbol Unit XMD*-W0606

XMD*-W1010

XMD*-W1616

XMD*-W2323

XMD*-W5454

XMD*-W7070


Rated control current input8) IN3 A 5.3 6.7



Rated input current ILN A DC 4.9 DC 8.1 DC 12.9 DC 18.8 DC 47.6 DC 61.7


Output voltage Uout V AC 0 ... 500

Output current Iout A

Axis 1:AC 2

Axis 2:AC 2

Axis 1:AC 3.3Axis 2:AC 3.3



Axis 1:AC 27Axis 2:AC 27

Axis 1:AC 35Axis 2:AC 35

Output frequency range10) fout Hz 0 ... 800 0 ... 1600






Tab. 2-6: UL ratings and dimensionsUL ratings and dimensions (XMQ*)

Description Symbol Unit XMQ*-WQ001 XMQ*-WQ002



UL‑Files E134201

Pollution degree 2


Mass m kg 10 15



Device width3) B mm 200 325

14/43




Description Symbol Unit XMQ*-WQ001 XMQ*-WQ002






Rated control current input8) IN3 A 12 14.3



Rated input current ILN A DC 64 DC 162

Required wire size in accordancewith NFPA 79 and UL 508 A (in‐ternal wiring);10)

ALN AWG

Axis 1: 8Axis 2: 10Axis 3: 14Axis 4: 14

Axis 1: 4Axis 2: 8

Axis 3: 10Axis 4: 14


Output voltage Uout V AC 0 ... 500

Output current Iout A

Axis 1: AC 27Axis 2: AC 18Axis 3: AC 6.7Axis 4: AC 3.3

Axis 1: AC 67Axis 2: AC 35Axis 3: AC 18Axis 4: AC 3.3








Tab. 2-7: UL ratings and dimensions




Rated power consumption control voltage input at UN3

Plus motor holding brake and control section, plus safety option

Distances

A Air intakeB Air outletC Mounting surface in control cabinetD Touch guard plate at device (thickness: 1.5 mm = dhor for indi‐

vidual supply); thus, with two individually supplied devicesmounted side by side there is no distance (0 mm) between thetouch guard plates, and below the touch guard plates there is adistance of 3 mm (2 × 1.5 mm)

dtop Distance topdbot Distance bottomdhor Distance horizontalFig. 2-1: Air intake and air outlet at device

16/43




2.3 Supply unitsUL ratings and dimensions (XVR)

Description Symbol Unit XVR*-W0048 XVR*-W0072 XVR*-W0100



UL‑Files E328841

Pollution degree 2


Mass m kg 16 20 27

Device height1) H mm 309 340.5








Rated control current input IN3 A 4


Rated input voltage, power8) ULN_nenn V AC 380Y/220V … 500Y/288V


Rated input current ILN A 76 109 150

Branch circuit protection fuse9) Class J Fuse 100A Class J Fuse 125A Class J Fuse 200A

Required wire size in accordancewith UL 508 A (internal wiring);10) ALN AWG 3 1/0 3/0


Output voltage Uout V DC 0 … 750

Output current Iout A 64 96 133




Description Symbol Unit XVR*-W0048 XVR*-W0072 XVR*-W0100

Maximum allowed DC bus power(ULN AC 400V) Pout kW 120 180 250








Tab. 2-8: UL ratings and dimensionsDistances

A Air intakeB Air outletC Mounting surface in control cabinetD Touch guard plate at device (thickness: 1.5 mm = dhor for indi‐

vidual supply); thus, with two individually supplied devicesmounted side by side there is no distance (0 mm) between thetouch guard plates, and below the touch guard plates there is adistance of 3 mm (2 × 1.5 mm)

dtop Distance topdbot Distance bottomdhor Distance horizontalFig. 2-2: Air intake and air outlet at device

18/43




2.4 China RoHS 2www.boschrexroth.com.cn/zh/cn/home_2/china_rohs2




20/43 ctrlX DRIVE Drive Controllers, Supply Units


3 Overview of documentations3.1 MotorsTitle Type of documentation Document typecode1)

DOK-MOTOR*-…

Material number

MS2NSynchronous Servomotors

Project Planning Manual MS2N*******-PRxx-EN-P R911347583

MS2SSynchronous Servomotors

Project Planning Manual MS2S*******-PRxx-EN-P R911410075

MS2ESynchronous Servomotorsacc. to ATEX Directive 2014/34/EU

Project Planning Manual MS2E*******-PRxx-EN-P R911394140

MSKSynchronous Servomotors

Project Planning Manual MSK********-PRxx-EN-P R911296289

MSKSynchronous Servomotorsfor Potentially Explosive Areas

Project Planning Manual MSK*EXGIIK3-PRxx-EN-P R911312709

MKE Synchronous MotorsSynchronous Servo Motorsfor Potentially Explosive Areasacc. to ATEX and UL / CSA

Project Planning Manual MKE*GEN2***-PRxx-EN-P R911297663

MAD / MAFAsynchronous Motors MAD / MAF

Project Planning Manual MAD/MAF****-PRxx-EN-P R911295781

MLFSynchronous Linear Motors

Project Planning Manual MLF********-PRxx-EN-P R911293635

ML3Self-Cooled Linear Motors

Project Planning Manual ML3X*******-PRxx-EN-P R911389760

MCLIronless Linear Motors MCL

Project Planning Manual MCL********-PRxx-EN-P R911330592

1) In the documentation typecodes, "xx" is a placeholder for thecurrent edition of the documentation (e.g.: PR01 is the first edi‐tion of a Project Planning Manual)

Tab. 3-1: Documentations – motors


Overview of documentations


4 Instructions for use4.1 Overcurrent protection

Protect the components against overcurrent:● Branch circuit protection has to be provided externally.

For the North American sales region, individual branch circuit protectionon the mains side is mandatory before each device.

● Dimension the branch circuit protection according to the "Branch circuitprotection fuse" data (see Ratings and dimensions)

Lethal electric shock from live parts with morethan 50 V!Risk of burns by hot housing surfaces! Riskof fire!

WARNING

The opening of the branch-circuit protective device may be an indication thata fault current has been interrupted. To reduce the risk of fire or electricshock, current-carrying parts and other components of the controller shouldbe examined and replaced if damaged. If burnout of the current element ofan overload relay occurs, the complete overload relay must be replaced.

4.2 Connection4.2.1 General information

Apart from the indicated connections, it is necessary to wire theBb contact at the control section for signaling the readiness foroperation of the drive controller (see Project Planning Manual"Rexroth IndraDrive Drive Controllers Control Sections").

For proper function of the motor thermal management connect the motorthermal sensor as described in the wiring diagram. Otherwise motor overtem‐perature sensing is not provided by the drive.For Rexroth motors with data memory in the motor encoder, such as MSK,the motor overload protection level is set automatically while connecting themotor to the drive. There is no adjustment necessary. Otherwise refer to theRexroth firmware documentation.


Instructions for use


4.2.2 Overall connection diagram XCS*-W0054…W0070

XD01 MainsXD02 DC busXD03 MotorXD04 Internal/external braking resistorXD10 Control voltageXF21, XF22 CommunicationXG02 Ready for operation relay contactXG03 Motor temperature monitoring and motor holding brakeXG20 Digital encoderXG21 Multi-encoder (optional)XG31 Digital inputs/outputs; analog inputXG4x Safety technologyFig. 4-1: Overall connection diagram XCS*-W0054…W0070 Symbols: See chapter 4.2.14 "Symbols (connection diagram)" on page 36

24/43




4.2.3 Overall connection diagram XCS*-W01xx

XD01 MainsXD02 DC busXD03 MotorXD04 Internal/external braking resistorXD10 Control voltageXF21, XF22 CommunicationXG02 Ready for operation relay contactXG03 Motor temperature monitoring and motor holding brakeXG20 Digital encoderXG21 Multi-encoder (optional)XG31 Digital inputs/outputs; analog inputXG4x Safety technologyFig. 4-2: Overall connection diagram XCS*-W01xx Symbols: See chapter 4.2.14 "Symbols (connection diagram)" on page 36




4.2.4 Overall connection diagram XCS*-W02xx

XD01 MainsXD02 DC busXD03 MotorXD04 Internal/external braking resistorXD10 Control voltageXF21, XF22 CommunicationXG02 Ready for operation relay contactXG03 Motor temperature monitoring and motor holding brakeXG20 Digital encoderXG21 Multi-encoder (optional)XG31 Digital inputs/outputs; analog inputXG4x Safety technologyFig. 4-3: Overall connection diagram XCS*-W02xx Symbols: See chapter 4.2.14 "Symbols (connection diagram)" on page 36

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4.2.5 Overall connection diagram XCD

XD01 MainsXD02 DC busXD04 Internal/external braking resistorXD10 Control voltageXF21, XF22 CommunicationXG02 Ready for operation relay contactXG20 Digital encoderXG21 Multi-encoder (optional)XG31 Digital inputs/outputs; analog inputXG4x Safety technologyXZ03 Motor, motor temperature monitoring, motor holding brakeFig. 4-4: Overall connection diagram XCD Symbols: See chapter 4.2.14 "Symbols (connection diagram)" on page 36




4.2.6 Overall connection diagram XMS*-W0006…W0036

XD02 DC busXD10 Control voltageXF21, XF22 CommunicationXG20 Digital encoderXG21 Multi-encoder (optional)XG31 Digital inputs/outputs; analog inputXG4x Safety technologyXZ03 Motor, motor temperature monitoring, motor holding brakeFig. 4-5: Overall connection diagram XMS*-W0006…W0036 Symbols: See chapter 4.2.14 "Symbols (connection diagram)" on page 36

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XD02 DC busXD03 MotorXD10 Control voltageXF21, XF22 CommunicationXG03 Motor temperature monitoring and motor holding brakeXG20 Digital encoderXG21 Multi-encoder (optional)XG31 Digital inputs/outputs; analog inputXG4x Safety technologyFig. 4-6: Overall connection diagram XMS*-W0054…W0090 Symbols: See chapter 4.2.14 "Symbols (connection diagram)" on page 36





XD02 DC busXD03 MotorXD10 Control voltageXF21, XF22 CommunicationXG03 Motor temperature monitoring and motor holding brakeXG20 Digital encoderXG21 Multi-encoder (optional)XG31 Digital inputs/outputs; analog inputXG4x Safety technologyFig. 4-7: Overall connection diagram XMS*-W0100…W0280 Symbols: See chapter 4.2.14 "Symbols (connection diagram)" on page 36

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4.2.9 Overall connection diagram XMD*-W0606…W2323

XD02 DC busXD10 Control voltageXF21, XF22 CommunicationXG02 Ready for operation relay contactXG20 Digital encoderXG21 Multi-encoder (optional)XG31 Digital inputs/outputs; analog inputXG4x Safety technologyXZ03 Motor, motor temperature monitoring, motor holding brakeFig. 4-8: Overall connection diagram XMD*-W0606…W2323 Symbols: See chapter 4.2.14 "Symbols (connection diagram)" on page 36




4.2.10 Overall connection diagram XMD*-W5454…W7070

XD02 DC busXD03 MotorXD10 Control voltageXF21, XF22 CommunicationXG02 Ready for operation relay contactXG03 Motor temperature monitoring and motor holding brakeXG20 Digital encoderXG21 Multi-encoder (optional)XG31 Digital inputs/outputs; analog inputXG4x Safety technologyFig. 4-9: Overall connection diagram XMD*-W5454…W7070 Symbols: See chapter 4.2.14 "Symbols (connection diagram)" on page 36

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4.2.11 Overall connection diagram XMQ*-WQ001

X…A, X…B Connection points of axis module A or BXxxx.1/2.A/B Xxxx.1.A (Axis1: 54 A); Xxxx.2.A (Axis2: 36 A);

Xxxx.1.B (Axis3: 20 A); Xxxx.2.B (Axis4: 10 A)XD02 DC busXD03 MotorXD10 Control voltageXF21, XF22 CommunicationXG02 Ready for operation relay contactXG03 Motor temperature monitoring and motor holding brakeXG20 Digital encoderXG21 Multi-encoder (optional)XG31 Digital inputs/outputs; analog inputXG4x Safety technologyXZ03 Motor, motor temperature monitoring, motor holding brakeFig. 4-10: Overall connection diagram XMQ*-WQ001 Symbols: See chapter 4.2.14 "Symbols (connection diagram)" on page 36




4.2.12 Overall connection diagram XMQ*-WQ002

X…A, X…B, X…C Connection points of axis module A, B or CXxxx.A/C; Xxxx.1/2.B Xxxx.A (Axis1: 100 A); Xxxx.1.B (Axis2: 70 A);

Xxxx.2.B (Axis3: 36 A); Xxxx.C (Axis4: 10 A)XD02 DC busXD03 MotorXD10 Control voltageXF21, XF22 CommunicationXG02 Ready for operation relay contactXG03 Motor temperature monitoring and motor holding brakeXG20 Digital encoderXG21 Multi-encoder (optional)XG31 Digital inputs/outputs; analog inputXG4x Safety technologyXZ03 Motor, motor temperature monitoring, motor holding

brakeFig. 4-11: Overall connection diagram XMQ*-WQ002 Symbols: See chapter 4.2.14 "Symbols (connection diagram)" on page 36

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4.2.13 Overall connection diagram XVR

XD01 MainsXD02 DC busXD03 XLI-XVR mainsXD04 External or internal braking resistorXD10 Control voltageXF21, XF22 CommunicationXG02 Ready for operation relay contactXG20 XLI busXG31 Digital inputs/outputs; analog inputXLI Mains connection moduleXVR Supply unitFig. 4-12: Overall connection diagram XVR Symbols: See chapter 4.2.14 "Symbols (connection diagram)" on page 36




4.2.14 Symbols (connection diagram)

Symbol Description

Pin

Female connector

Male connector (pin at connector; female [device])

Spring terminal (female [connector], pin at device)

Screw terminal (female [connector], pin at device)

Screw connection at device

Electrical connection at device housing (e.g., for cable shield con‐nection)

Tab. 4-1: Symbols (connection diagram)

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4.2.15 Connection points

Symbols used to describe the connection points

Screw terminalblock

Spring terminal Thread Max. connection cross section Strippedlength

Max. tighteningtorque

Tab. 4-2: Symbols

Connection point Device 1)

AWG (mm2) in (mm) lbf in (Nm)

A, B, C, D, E, F, G,H, I, J, K, L

Ring cable lug M5 - 24.8 (2.8)

A Ring cable lug M5 - 44.3 (5)

E Ring cable lug M8 - 70.8 (8)

H, I, J, K Ring cable lug M6 - 44.3 (5)

D 6 (16) 0.5 (12) 13 (1.5)

G 8 (10) 0.6 (15) -

XD01 A , I 4 (35) 0.71 (18) 39.9 (4.5)

D 6 (16) 0.5 (12) 13 (1.5)

E, K 4/0 (120); M10 - 177 (20)

G 8 (10) 0.6 (15) -

H, J 1/0 (50); M6 - 44.3 (5)

XD03 A , F 4 (35) 0.7 (18) 39.9 (4.5)

B, D, F 8 (10) 0.6 (14) 16 (1.8)

L 6 (16) 0.5 (12) 13 (1.5)

E 4/0 (120); M10 - 177 (20)

G 8 (10) 0.6 (14) -

H 1/0 (50); M6 - 44.3 (5)

XZ03 2) B, C, F, G 8 (10) 0.5 (12) -

XG03 B, D, F, L 16 (1.5) 0.4 (10) -

A, E, F, H 12 (2.5) 0.4 (10) -

XZ03 3) B, C, F, G 16 (1.5) 0.4 (10) -

XD04 D, G 8 (10) 0.5 (12) -

A, H, I, J 6 (16) 0.6 (14) 16 (1.8)

E, K 4 (35) 0.71 (18) 39.9 (4.5)




Connection point Device 1)

AWG (mm2) in (mm) lbf in (Nm)

XD02 A, B, C, D, E, F, G,H, I, J, K, L

- - 24.8 (2.8)

XD10 A, B, C, D, E, F, G,H, I, J, K, L

8 (6) 0.4 (10) -

1) Device:A XCS*-W0100, -0120; XMS*-W0100, -0120B XMQ*-WQ001C XMS*-W0006, -0010, -0016, -0023, -0036; XMD*-W0606,

-1010, -1616, -2323, -3636D XCS*-W0054, -0070; XMS*-W0054, -0070; XMD*-W5454,

-7070E XCS*-W0210, -0250, -0280; XMS*-W0210, -0250, -0280F XMQ*-WQ002G XCD*-W2323H XCS*-W0150, -0180I XVR*-W0048J XVR*-W0072K XVR*-W0100L XMS*-W00902) Motor3) Motor temperature monitoring, motor holding brakeTab. 4-3: Connection points

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5 Service and supportOur worldwide service network provides an optimized and efficient support.Our experts offer you advice and assistance should you have any queries.You can contact us 24/7.

Service Germany Our technology-oriented Competence Center in Lohr, Germany, is responsi‐ble for all your service-related queries for electric drive and controls.Contact the Service Hotline and Service Helpdesk under:

Phone: +49 9352 40 5060Fax: +49 9352 18 4941E-mail: [email protected]: http://www.boschrexroth.com

Additional information on service, repair (e.g. delivery addresses) and trainingcan be found on our internet sites.

Service worldwide Outside Germany, please contact your local service office first. For hotlinenumbers, refer to the sales office addresses on the internet.

Preparing information To be able to help you more quickly and efficiently, please have the followinginformation ready:● Detailed description of malfunction and circumstances● Type plate specifications of the affected products, in particular type co‐

des and serial numbers● Your contact data (phone and fax number as well as your e-mail ad‐

dress)


Service and support


mailto:[email protected]

http://www.boschrexroth.com

IndexAAdditional documentations.................................. 21Ambient conditions................................................ 5

CConditions

Ambient and operating conditions.................... 5Connection

Connection diagram (XCD)............................ 27Connection diagram (XCS)................ 24, 25, 26Connection diagram (XMD)..................... 31, 32Connection diagram (XMQ*-WQ001)............ 33Connection diagram (XMQ*-WQ002)............ 34Connection diagram (XMS)............................ 28Connection diagram (XVR)............................ 35

Connection diagramSymbols......................................................... 36XCD............................................................... 27XCS.................................................... 24, 25, 26XMD......................................................... 31, 32XMQ*-WQ001................................................ 33XMQ*-WQ002................................................ 34XMS............................................................... 28XVR................................................................ 35

Connection points............................................... 37

DData

Ambient conditions........................................... 5Operating conditions........................................ 5

Dimensions........................................................... 5Distances...................................................... 16, 18Documentation

Motors............................................................ 21Overview........................................................ 21Reference documentations............................ 21

HHelpdesk............................................................. 39Hotline................................................................. 39

IInstructions for use.............................................. 23Intended use......................................................... 4

MMotor

Documentation............................................... 21

OOperating conditions............................................. 5Overcurrent protection........................................ 23

PPower consumption.............................................. 5Project Planning Manuals................................... 21

RRatings.................................................................. 5Ratings and dimensions........................................ 5Reference documentations................................. 21RoHS

China RoHS 2................................................ 19

SSafety instructions................................................. 1Service hotline.................................................... 39Support............................................................... 39Symbols

Connection diagram....................................... 36

UUse

Instructions..................................................... 23Intended........................................................... 4

VVoltage load capacity............................................ 5

XXCD

Connection diagram....................................... 27XCS

Connection diagram........................... 24, 25, 26XD01................................................................... 37XD02................................................................... 37XD03................................................................... 37XD04................................................................... 37XD10................................................................... 37XG03................................................................... 37XMD

Connection diagram................................. 31, 32XMQ*-WQ001

Connection diagram....................................... 33XMQ*-WQ002

Connection diagram....................................... 34XMS

Connection diagram....................................... 28XVR

Connection diagram....................................... 35XZ03................................................................... 37


Index

Notes


Bosch Rexroth AGP.O. Box 13 5797803 Lohr a.Main, GermanyBgm.-Dr.-Nebel-Str. 297816 Lohr a.Main, GermanyPhone +49 9352 18 0Fax +49 9352 18 8400www.boschrexroth.com/electrics

*R911392530*R911392530

DOK-XDRV**-X*****UL***-IN02-EN-P

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