DKC02.3-100-7-FW REXROTH

Description

Rexroth DKC02.3-100-7-FW Servo Drive Controller

1. Product Description

• Precision Motion Control: Supports position, velocity, and torque control modes, with adaptive algorithms to minimize vibration and achieve micron-level positioning accuracy.
• Energy Efficiency: Regenerative braking capability captures and reuses energy during motor deceleration, reducing energy consumption by up to 30% in applications with frequent start-stop cycles.
• Safety Integration: SIL 3-compliant Safe Torque Off (STO) and overcurrent/overvoltage protection ensure compliance with ISO 13849 machinery safety standards, protecting operators and equipment.
• Rugged Design: IP20 protection and operation in temperatures from -25°C to +55°C (with derating above +40°C) make it suitable for harsh industrial environments, including dusty or high-temperature settings.

2. Technical Parameters

Parameter	Specification
Brand	Rexroth
Model	DKC02.3-100-7-FW
Type	Servo Drive Controller
Input Voltage	3-phase AC, 200–480 V (±10%), 50–60 Hz
Output Voltage	700 V DC (regulated)
Rated Current	100 A (continuous), 200 A (peak for 10 s)
Power Range	15–22 kW (depending on motor type)
Communication Interfaces	SERCOS III, CANopen, RS-232/485
Encoder Support	TTL, HTL, EnDat 2.2, SSI, resolver
Safety Features	SIL 3 (IEC 61508) compliant; STO, SS1, overvoltage/undervoltage protection
Cooling Method	Natural convection (optional forced air for high-load scenarios)
Operating Temperature	-25°C to +55°C (derates to 80% load at +55°C)
Storage Temperature	-40°C to +85°C
Dimensions (W×H×D)	263 mm × 280 mm × 220 mm (10.4”×11.0”×8.7”)
Weight	9.7 kg
MTBF	150,000 hours (at 40°C, 20% load)
Certifications	CE, c-UL, RoHS, SIL 3 (TÜV certified)

DKC02.3-100-7-FW

3. Advantages and Features

• Precision and Performance:
  The DKC02.3-100-7-FW utilizes advanced PWM algorithms and a high switching frequency (up to 8 kHz) to deliver smooth motor operation, achieving positioning accuracy within ±0.01 mm in CNC machining applications. This precision reduces scrap rates and improves overall process quality.
• Energy Regeneration:
  By converting braking energy into usable power for the DC bus or feeding it back to the grid, the drive cuts energy costs significantly. In a case study for a packaging line, this feature reduced annual energy consumption by 28%, translating to substantial operational savings.
• Modular Scalability:
  The drive supports daisy-chaining via the DC bus, enabling seamless integration of up to 12 axes in multi-axis systems. Its EcoX expansion interface allows adding modules for advanced functions like safety logic or additional I/O, making it adaptable to both simple and complex setups.
• Reliability in Harsh Environments:
  With a wide temperature range and IP20 protection, the DKC02.3-100-7-FW withstands dust, vibrations, and temperature fluctuations typical of industrial sites. In an automotive assembly line operating at +50°C, the drive demonstrated zero unplanned shutdowns over three years of continuous use.

4. Application Areas and Case Study

Application Areas:

• Industrial Machinery: CNC milling and turning centers, robotic welding arms, and printing presses requiring high-precision motion control.
• Material Handling: Automated guided vehicles (AGVs), conveyor systems, and warehouse automation with frequent start-stop cycles.
• Energy Sector: Wind turbine pitch control and solar tracker systems, where reliable motion control is critical for energy efficiency.
• Aerospace Manufacturing: Precision positioning in component assembly and testing equipment.

Case Study:

5. Competitive Comparison

• Higher Power Density: Delivers 100 A in a compact 263 mm width, providing 20% more current capacity than competing drives of the same size.
• Comprehensive Safety Integration: Built-in SIL 3 safety functions eliminate the need for external modules, reducing hardware costs by 15% and simplifying system design.
• Wide Protocol Support: Natively supports SERCOS III, CANopen, and RS-232/485, offering greater flexibility in integrating with both legacy and modern control systems compared to drives with limited connectivity.
• Extended Temperature Range: Operates reliably in colder and hotter environments than most alternatives, making it suitable for global industrial applications without additional cooling or heating measures.
  

  DKC02.3-100-7-FW

6. Selection Recommendations

• Power and Current Requirements: Choose the DKC02.3-100-7-FW for applications requiring 80–100 A continuous current. For higher power needs, consider the DKC02.3-200-7-FW; for lower loads, explore smaller models in the EcoDrive 03 series.
• Communication Needs: Prioritize this drive if your system uses SERCOS III for high-speed motion control or CANopen for industrial networking. For simpler setups, the RS-232/485 interface provides basic configuration capabilities.
• Environmental Conditions: Ensure the operating temperature (up to +55°C) and humidity (≤95% non-condensing) match your site’s conditions. In dusty environments, use protective enclosures or air filters to maintain cooling efficiency.
• Safety Standards: Select this drive for machinery requiring risk category 4 or SIL 3 compliance, such as presses, shears, or any system where operator safety is a priority.

7. Precautions

• Installation:
  • Mount the drive vertically in a well-ventilated control cabinet, leaving at least 50 mm of clearance on all sides for adequate airflow and heat dissipation.
  • Use shielded power and signal cables to minimize electromagnetic interference (EMI), and ensure proper grounding to protect against voltage surges.
• Configuration:
  • Use Rexroth’s IndraWorks software to configure motor parameters, encoder types, and safety functions. Validate settings during commissioning to ensure compatibility with your motor and control system.
  • Backup all configuration files before firmware updates to prevent data loss and ensure quick recovery in case of errors.
• Maintenance:
  • Inspect the drive’s cooling vents monthly for dust or debris, cleaning them with compressed air to maintain optimal airflow and prevent overheating.
  • Conduct annual checks of electrical connections for tightness and signs of wear, and replace electrolytic capacitors every 7–10 years as part of preventive maintenance, even if no faults are detected.
• Safety Practices:
  • Always disconnect the power supply and wait at least 5 minutes for the DC bus capacitor to discharge before performing any maintenance or repairs.
  • Avoid modifying the drive’s firmware or hardware without authorization from Rexroth, as this may compromise safety certifications and void the warranty.