Bosch Resxroth HVE02.2-W018N Instruction Manual Download Page 1

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Electric Drives

and Controls

Hydraulics

Linear Motion and

Assembly Technologies

Pneumatics

Service

Rexroth Diax 04

HVE and HVR

2nd Generation Power Supply Units

R911320339

Edition 01

Instruction Manual

Summary of Contents for Resxroth HVE02.2-W018N

Page 1: ...Electric Drives and Controls Hydraulics Linear Motion and Assembly Technologies Pneumatics Service Rexroth Diax 04 HVE and HVR 2nd Generation Power Supply Units R911320339 Edition 01 Instruction Manual ...

Page 2: ...orbidden 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 is for product description purposes only and may not be deemed to be guaranteed unless expressly confirmed in the contract All rights are reserved with respect to the content of this documentation and the...

Page 3: ... Delivery 2 2 3 Ratings and Dimensions 3 1 3 1 HVE 3 1 3 2 HVR 3 2 4 Reference Documentation 4 1 4 1 Overview 4 1 5 Instructions for Use 5 1 5 1 Overcurrent Protection 5 1 5 2 Connections 5 1 Wiring Diagram Supply Unit HVE 5 1 Wiring Diagram Supply Unit HVR 5 2 Connection Diagram 5 3 X0 Additional component bus 5 5 X1 Connection for integrated bus connections from neighboring device 5 6 X2 Service...

Page 4: ...connection 5 16 X12 Ground connection 5 17 X13 Optional choke connection only HVE 5 17 5 3 Installation 5 19 General Information on How to Install the Drive Controller 5 19 Sizing of Enclosure and Control Cabinet 5 20 6 Appendix 6 1 6 1 Discharging of DC Bus Capacitors 6 1 6 2 Discharging Device 6 2 7 Index 7 1 ...

Page 5: ...fety regulations to ground them and to mark them according to the requirements of safe work practices These persons must have adequate safety equipment and be trained in first aid Technical data connections and operational conditions are specified in the reference documentations for the product and must be followed at all times If the products take the form of hardware then they must remain in the...

Page 6: ...oints of a component while power is turned on Install the covers and guards provided with the equipment properly before switching the device on Before switching the equipment on cover and safeguard live parts safely to prevent contact with those parts A residual current operated circuit breaker or r c d cannot be used for electric drives Indirect contact must be prevented by other means for exampl...

Page 7: ...lly entering the machine s range of motion use safety fences use safety guards use protective coverings install light curtains or light barriers Fences and coverings must be strong enough to resist maximum possible momentum Mount the emergency stop switch in the immediate reach of the operator Verify that the emergency stop works before startup Don t operate the device if the emergency stop is not...

Page 8: ...or housings on drive controllers or chokes Danger of burns Do not touch surfaces of device housings and chokes in the proximity of heat sources Danger of burns Do not touch housing surfaces of motors Danger of burns According to operating conditions temperatures can be higher than 60 C 140 F during or after operation Before accessing motors after having switched them off let them cool down for a s...

Page 9: ...resentative will help you with the current status of available versions HVE HVE 02 2 W018N Line Product HVE Example Other design Nominal power 30 kW 75 kW 030 075 N hve_typenschluessel_en fh7 02 18 kW 018 Design 2 Cooling mode W 03 04 Air internal with built in blower L none increased loading capacity for external DC bus capacitors HVE03 x up to 100 mF HVE04 x up to 200 mF Fig 2 1 Type code HVE ...

Page 10: ...entification of supplier Serial Number Part number Example K25 03 means week 25 in year 2003 Production week Producing Country Fig 2 3 Type plate 2 2 Scope of Delivery The supply units HVx0x 2 W0xxx resp the additional components HZS HZB HZK and HZF are delivered with connectors plugged on with mounted touch guard with strands for DC bus connection to neighboring device with grounding brackets for...

Page 11: ...evice 4 dtop mm 300 minimum distance on the bottom of the device 5 dbot mm 100 rated control voltage input UL 6 UN3 V 3 x 380 480 rated power consumption control voltage input without holding brake without control section at UN3 DC 24 V UL 7 PN3 W 500 short circuit current rating SCCR symmetrical amperes UL 8 ISCCR A rms 42000 rated input voltage power UL 9 V 3 x 380 480 tolerance rated input volt...

Page 12: ...less The drive series shall be used with listed AC input line fuses or listed circuit breakers specified in this documentation 9 HDS HDD HZB HZK DC bus L L HVE HVR mains input U V W 10 at PDC_cont 11 class J branch circuit fuse 12 find value for tightening torque in project planning manual electrical terminals 13 copper wire PVC insulation conductor temperature 90 C Table 13 5 1 Ta 40 C 14 plus di...

Page 13: ...80 branch circuit protection fuse UL 11 25 70 100 field wiring material UL 12 Use 60 75 C copper wire only use class 1 wire only or equivalent required wire size section according UL 508 A internal wiring at IL_cont UL 13 ALN AWG 6 6 2 maximum output voltage UL Uout V 750 dc maximum output current UL Iout_max A 13 33 60 power dissipation at continuous current Iout_cont and continuous DC bus power ...

Page 14: ...ns Rexroth Diax 04 HVE HVR DOK DIAX04 HVE HVR UL IB01 EN P A air intake B air outlet C mounting surface in control cabinet dtop distance top dbot distance bottom Fig 3 4 Air intake and air outlet at drive controller Distances ...

Page 15: ...S 03VRS WA01 EN P DIAX04 Drive With Servo Function Analog and Parallelinterface Functional Description DOK DIAX04 ASE 02VRS FKB1 EN P DIAX04 Drive With Servo Function Analog and Parallelinterface Troubleshooting Guide DOK DIAX04 ASE 02VRS WAR1 EN P DIAX04 Drive With Main Spindle Function Analog And Parallelinterface Functional Description DOK DIAX04 AHS 03VRS FKB1 EN P DIAX04 Drive With Main Spind...

Page 16: ...4 2 Reference Documentation Rexroth Diax 04 HVE HVR DOK DIAX04 HVE HVR UL IB01 EN P ...

Page 17: ...imum values voltage and current or voltage and percent of FLA of the fuses FLA Full Load Ampacity 5 2 Connections Wiring Diagram Supply Unit HVE mains PE mains Filter NFD load earth rail to the motors power connection shielded control cabinet compartment or intermediate panel control cabinet connecting clamps main switch distributor clamps fuse B01EMV fh7 HVE HDS HDS Fig 5 1 Wiring Diagram Supply ...

Page 18: ...VR mains PE HVR HDS HDS earth rail to the motors shielded control cabinet compartment or intermediate panel control cabinet connecting clamps main switch distributor clamps fuse B02EMV fh7 HZF power connection KD control voltage connection shielded cable ground connection Fig 5 2 Wiring Diagram Supply Unit HVR ...

Page 19: ... NO K1 NC K1 NC X6 1 2 3 4 5 6 Bb1 UD VW X7 7 8 BVW power supply and ground connection of drive controllers X1 bridged at delivery 2 1 2 3 4 5 6 ready to operate prewarning Bleeder prewarning power voltage OK AP_HVE fh7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 power supply communication with auxiliary modules HZN bleeder etc ZKS Off ZKS Off X3 1 2 3 4 5 6 ZKS ON OFF On On 1 2 3 4 5 6 max...

Page 20: ...1 NC X6 1 2 3 4 5 6 Bb1 UD VW X7 power supply and ground connection of drive controllers X1 ready to operate prewarning power voltage OK n c power supply X2 service interface n c n c X0 11 12 13 14 15 16 17 18 19 20 supply and communication with auxiliary modules HZN bleeder etc 1 2 3 4 5 6 7 8 9 10 bridged at delivery L2 L1 L3 L2 L1 L3 X8 control voltage supply 1 2 3 4 Q1 U1 V1 W1 U2 V2 W2 PE KDx...

Page 21: ...on multi core mm Wire size in AWG gauge No 0 14 1 5 0 25 1 5 28 16 Fig 5 7 Connection cross section 0 22 Nm Ap_X0_hve fh7 X0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 X4 X2 X3 X0 X7 Fig 5 8 Terminal X0 at the additional component HZS Note At delivery terminal 1 is jumpered with 5 6 with 10 11 with 15 and 16 with 20 If there aren t any additional components HZB used the HVx power supply un...

Page 22: ... the devices The maximum length of the ribbon cable is 1 m when using extensions Note This is an internal connection between power supply unit and drive controller X2 Service interface The X2 interface is only used for service purposes Therefore this manual does not contain any further information on this interface X3 Emergency stop circuit X3 fh7 1 2 3 4 5 6 1 2 3 4 5 6 ZKS ZKS OFF ON ON OFF Fig ...

Page 23: ...arting current A Holding current A HVE02 03 24 8 0 45 HVE04 24 20 1 HVR 24 8 1 Fig 5 15 Technical data of the DC bus As an additional installation protection in the event of drive electronic problems the DC bus is short circuited with an open DC bus input Motors with permanent magnet excitation can in this case still be shutdown in a controlled manner WARNING Injury to the personnel due to uncontr...

Page 24: ...er of 16 switching actuations per minute applies to the internal contactors K1 and K2 The number of switching actuations service life of the contact elements is 1 million for HVR and HVE units however only if the contactor is switched current less If switched in loaded condition e g when emergency stop is released the number of switching actuations for both unit families and types of contactors is...

Page 25: ... coupled in short shielded lines The load carrying ability of the control voltages is correspondingly reduced by the drive controllers The control voltage outputs are short circuit proof The maximum permissible load must not be exceeded in order not to endanger the functions of the drives X5 Mains connection DANGER Lethal electric shock caused by live parts with more than 50 V Connect the protecti...

Page 26: ...re size in AWG gauge No HVR02 2 W10N HVR02 2 W25N HVE02 2 W18N 2 5 10 2 5 16 12 6 HVR03 2 W45N HVE03 2 W30N 2 5 16 2 5 35 12 2 HVE04 2 W75N 16 50 16 50 6 0 Fig 5 25 Connection cross section Device Tightening torque HVR02 2 W10N HVR02 2 W25N HVE02 2 W18N 2 Nm HVR03 2 W45N HVE03 2 W30N 4 Nm HVE04 2 W75N 6 Nm Fig 5 26 Tightening torques X5 V device internal device external U W L1 L2 L3 PE AP_X5 fh7 F...

Page 27: ...esign Cross section single core mm Cross section multi core mm Cross section in AWG gauge No 0 2 2 5 0 25 2 5 24 12 Fig 5 30 Connection cross section 0 5 Nm The acknowledge outputs are on terminal X6 X2 X3 X4 X6 X7 acknowledge power ON 1 2 3 4 5 6 K1 NO K1 NC K1 NC X6 acknowledge power OFF acknowledge power OFF 1 1 only with HVE not with HVR R03hva1B fh7 X0 Fig 5 31 Terminal assignment X6 Continuo...

Page 28: ...restricted guidance between the acknowledge power OFF contact and the main contacts of the mains contactor in the power supply unit On the HVE power supply unit there are two brake contacts labeled as Acknowledge power Off led to the outside of the unit X7 Ready to operate and other messages hve_X7 fh7 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 Bb1 Bb1 UD UD TVW TVW BVW BVW hzs_X7 fh7 1 2 3 4 5 6 7 8 1 2 3 4...

Page 29: ...ltages have to refer to potential ground Ready to operate Bb1 The Bb1 contact of the power supply unit is of higher ranking significance It signals that the drive is ready to receive power Only if closed the locks within the unit allow switching the mains contactor to the power supply unit In the event of a fault the power contactor is shut off and the Bb1 contact opens If this contact opens then ...

Page 30: ...nent The mains contactor in the power supply unit interrupts the power supply after 30 seconds and the Bb1 contact opens Note If the installation requires that the drives are shut down in a position controlled fashion if there is a fault in the unit then the drives must be shutdown within 30 seconds Bleeder pre warning contact BVW The bleeder pre warning contact only exists in the HVE power supply...

Page 31: ...core mm Wire size in AWG gauge No 0 2 4 0 0 25 4 0 24 10 Fig 5 40 Connection cross section 0 5 Nm AP_X8hve fh7 X0 X6 X7 1 2 3 4 5 6 X8 X8 2u2 2v2 2w2 2u1 2v1 2w1 bridged at delivery X0 X6 X7 1 2 3 4 X8 X8 L1 L2 L3 n c AP_X8hvr fh7 HVE HVR Fig 5 41 Terminal assignment X8 Connection cross section Tightening torque Terminal assignment ...

Page 32: ...en connecting the DC bus make sure the polarity is correct If in special cases it is impossible to use the DC bus strands provided to make the connection the connection must be made using the shortest possible twisted wires line length within a drive package between two drive packages HZS application in stand alone operation max 2 x 1 m max 2 x 15 m max 2 x 30 m line cross section min 10 mm 2 but ...

Page 33: ...ble rear panel of device and mounting rail grounding bracket on the front see figure To ensure the connection of the devices to the protective conductor system connect the neighboring devices to both sides via the grounding brackets Abb 5 47 Grounding brackets X13 Optional choke connection only HVE 1L 2L hve_X13 fh7 hve04_X13 fh7 1L 2L HVE02 and HVE03 jumpered at delivery HVE04 not jumpered at del...

Page 34: ...umper from 1L to 2L HVE04 without jumper if the optional choke is not required a jumper has to be laid from 1L to 2L line cross section see below max voltage with reference to L DC 900 V voltage with reference to ground provided mains voltage max continuous current HVE02 03 70 A HVE04 150 A Fig 5 51 Load capacity line length max 10 m line cross section not smaller than cross section of supply feed...

Page 35: ...ngered components may only be stored or dispatched in conductive packaging Note Rexroth connection diagrams are only to be used for producing installation connection diagrams The machine manufacturer s installation connection diagrams must be used for wiring the installation Lay signal lines separately from the load resistance lines because of the occurrence of interference Transmit analog signals...

Page 36: ...evice line intake area of cooling air for lower device line outlet air to cooling unit supply air from cooling unit Fig 5 53 Example of arrangement for multiple line structure with components Arrangement of Cooling Units CAUTION Possible damage to the drive controller Operational safety of the machine endangered Note the following instructions Due to the operating principle condensation water is f...

Page 37: ...ustment to the maximum surrounding temperature and not lower Set cooling units with follow up temperature in such a way that the interior temperature of the control cabinet is no lower than the temperature of the surrounding air Set the temperature limitation to the maximum surrounding temperature Only use well sealed control cabinets so that moisture condensation cannot arise as a result of warm ...

Page 38: ...5 22 Instructions for Use Rexroth Diax 04 HVE HVR DOK DIAX04 HVE HVR UL IB01 EN P ...

Page 39: ...ith them Due to the operating principle the discharging time is the longer the bigger the energy store the capacitance value the higher the voltage to which the energy store has been charged the greater the resistance for discharging the capacitors Components of the drive system Rexroth IndraDrive have been dimensioned in such a way that after the energy supply was cut off the voltage value falls ...

Page 40: ... has to be dimensioned with 1000 ohm and at least 1000 W The discharging resistor and the contactor contact have to withstand the loads of practical operation for example in the case of frequent use of the discharging device of the occurring continuous power The contactor contact has to withstand the occurring direct voltage of min 1000 V The contactor contact has to withstand the occurring discha...

Page 41: ...ormation 5 19 Instructions for use 5 1 Interfaces acknowledging the power supply unit mains contactor 5 11 additional component bus 5 5 control voltage supply 5 14 control voltages 5 8 emergency stop circuit 5 6 integrated bus connections from neighboring device 5 6 ready to operate and other messages 5 12 service interface 5 6 M Mains connection 5 9 moisture condensation 5 21 O Optional choke con...

Page 42: ...egrated bus connections from neighboring device 5 6 X11 DC bus connection 5 16 X12 Ground connection 5 17 X13 Optional choke connection only HVE 5 17 X2 Service interface 5 6 X3 Emergency stop circuit 5 6 X4 interfaces control voltages 5 8 X5 Mains connection 5 9 X6 power supply unit mains contactor 5 11 X7 Ready to operate and other messages 5 12 X8 Control voltage supply 5 14 ...

Page 43: ......

Page 44: ...ny 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 Fax 49 0 93 52 40 49 41 service svc boschrexroth de www boschrexroth com ...

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