Bosch Rexroth Diax 04 Instruction Manual Download Page 1 | Manualshive

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Electric Drives

and Controls

Hydraulics

Linear Motion and

Assembly Technologies

Pneumatics

Service

Rexroth Diax 04

HDD and HDS

Drive Controllers 2nd Generation

R911320338

Edition 01

Instruction Manual

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Summary of Contents for Rexroth Diax 04

Page 1: ...Electric Drives and Controls Hydraulics Linear Motion and Assembly Technologies Pneumatics Service Rexroth Diax 04 HDD and HDS Drive Controllers 2nd Generation R911320338 Edition 01 Instruction Manual ...

Page 2: ... 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 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 t...

Page 3: ...ns 3 1 3 1 HDD02 2 and HDS02 2 W040N 3 1 3 2 HDS03 2 HDS05 2 3 3 4 Reference Documentations 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 Connection of Control Interfaces and Terminals 5 6 X1 Connector for integrated bus connections from the neighboring ...

Page 4: ...HDD HDS UL IB01 EN P General Information on How to Install the Drive Controller 5 15 Touch Guard at Devices 5 16 Sizing of Enclosure and Control Cabinet 5 16 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: ...safety 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 t...

Page 6: ... points 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 exam...

Page 7: ...tally 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 n...

Page 8: ...otor 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...

Page 9: ...ng 4 1 air internal with built in blower W 5 Rated current 40 A 040 75 A 075 100 A 100 200 A 200 300 A 300 6 Other versions 6 1 none N 7 Controller family 7 1 DIAX04 H 8 Command communication 8 1 ANALOG interface A 8 2 SERCOS interface S T 9 Function id code Determined and documented by Rexroth 9 1 e g 1 01 10 Version of function id Determined and documented by Rexroth 10 1 e g 1 01 11 Firmware 11...

Page 10: ...al with built in blower W 5 Rated current 5 1 16 A 016 40 A 040 6 Other versions 6 1 none N 7 Controller family 7 1 DIAX04 H 8 Command communication 8 1 SERCOS interface D 9 Function id code Determined and documented by Rexroth 9 1 e g 32 32 10 Version of function id Determined and documented by Rexroth 10 1 e g 1 01 11 Firmware 11 1 Indicator showing that firmware must be ordered as separate subi...

Page 11: ...cables for DC bus connection Connectors for HDD02 2 W0xxN HD32 X3 1 X3 2 X5 1 X5 2 X6 1 X6 2 X12 1 X12 2 for HDS0x 2 W0xxx RExx Connector Type X3 X5 X6 Mounting plate Shield connection motor cable Hose clamp small Hose clamp big HDS02 2 x x x x HDS03 2 x x x x HDS04 2 x x x x HDS05 2 x x x x x further parts for HDD02 2 2 hose clamps for mounting shield of motor cable 2 protection caps for interfac...

Page 12: ...2 4 Identification Rexroth Diax 04 HDD and HDS DOK DIAX04 HDD HDS UL IB01 EN P ...

Page 13: ...it current rating SCCR symmetrical amperes UL 7 ISCCR A rms 42000 rated input voltage power UL 8 V 530 670 maximum input current UL 9 IL_cont A 8 7 25 37 field wiring material UL 10 Use 60 75 C copper wire only use class 1 wire only or equivalent maximum output voltage UL Uout V 500 output number of phases UL 3 maximum output current UL Iout_max A 8 5 15 20 maximum output frequency UL fout Hz 1000...

Page 14: ... Rexroth Diax 04 HDD and HDS DOK DIAX04 HDD HDS UL IB01 EN P A air intake B air outlet C mounting surface in control cabinet dtop distance top dbot distance bottom Fig 3 2 Air intake and air outlet at drive controller Distances ...

Page 15: ... rating SCCR symmetrical amperes UL 7 ISCCR A rms 42000 rated input voltage power UL 8 V 530 670 maximum input current UL 9 IL_cont A 37 60 60 140 field wiring material UL 10 Use 60 75 C copper wire only use class 1 wire only or equivalent maximum output voltage UL Uout V 500 output number of phases UL 3 maximum output current UL Iout_max A 40 50 120 175 maximum output frequency UL fout Hz 1000 po...

Page 16: ... Rexroth Diax 04 HDD and HDS DOK DIAX04 HDD HDS 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 17: ...HS 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 Spin...

Page 18: ...4 2 Reference Documentations Rexroth Diax 04 HDD and HDS DOK DIAX04 HDD HDS UL IB01 EN P ...

Page 19: ...aximum 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 Suppl...

Page 20: ... HVR 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 21: ...as per relevant terminal diagrams PTC NTC depends on motor type U Additional plugin module not with HDS02 Additional plugin module Additional plugin module Command communications module 7 0VB UB TM TM BR BR 24V Ext 0V Ext 24V XS1 shield for motor cable L L power voltage bus rails DC bus U2 U3 U4 U5 X1 Bus connection from previous drive controller or supply module the following drive controller TxD...

Page 22: ...S3 n c R1 4 6 11 13 1 9 12 10 8 5V_G2 0VM A _G2 Feedback connector 1Vss X7 2 6 5 4 3 UM_G2 7 9 7 4 2 3 12 8 1 5 6 10 B _G2 B _G2 R _G2 R _G2 n c PK 0 252 GY 0 252 RD 0 252 BK0 252 GN 0 252 BN 0 252 WH 1 02 BN 1 02 2 0VM A _G2 11 13 14 15 SERCOS Interface Zehnerwert Antriebsadresse Einerwert S3 2 HIGH S2 2 LOW 1 2 3 4 5 6 7 8 9 Referenzschalter pos Fahrbereichsgrenzschalter neg Fahrbereichsgrenzsch...

Page 23: ...6 10 WH 0 52 cos cos sin sin n c GN 0 252 BN 0 252 PK 0 252 GY 0 252 BN 0 52 BK 0 252 RD 0 252 BU 0 252 VT 0 252 MHD MKD MKE IDO SDI SCL FS 0VM S2 S4 S1 S3 n c R1 1 9 12 10 8 5V_G2 0VM A _G2 Feedback connection 2 1Vpp X7 1 6 5 4 3 UM_G2 7 9 7 4 2 3 12 8 1 5 6 10 B _G2 B _G2 R _G2 R _G2 n c PK 0 252 GY 0 252 RD 0 252 BK0 252 GN 0 252 BN 0 252 WH 1 02 BN 1 02 2 0VM A _G2 11 13 14 15 4 6 11 13 SERCOS...

Page 24: ...ntroller with the help of the flat ribbon cable integrated into the units Maximum length here also equals one meter if extensions are used Ap5336f1 FH7 Fig 5 6 Connector X1 Type No of pins Design ribbon cable connector 30 connector at the unit ribbon cable bushing 30 bushing at the ribbon cable Fig 5 7 Design Note This is an internal connection between the supply unit and the drive controller X5 D...

Page 25: ...ign Cross section single wire mm Cross section multi core wire mm Cross section in AWG gauge no HDD02 HDS02 0 2 4 0 2 4 24 10 HDS03 2 5 10 4 16 12 4 HDS04 2 5 16 2 5 35 12 2 HDS05 16 50 16 50 6 0 Fig 5 12 Connection cross section X5 DC Bus Motor connection HDD02 HDS02 3 Nm 0 5 0 6 Nm HDS03 3 Nm 2 Nm HDS04 3 Nm 4 Nm HDS05 3 Nm 6 Nm Fig 5 13 Tightening torques X5 Design Connection cross section Tigh...

Page 26: ...conductor connection a separately shielded pair of wires for the motor temperature monitor a separately shielded pair of wires for the motor holding brake a complete shield mounted to shield attachment The motor power cable is available as a ready made cable from Rexroth The cable can also be made of four twisted individual supply wires 3 phases 1 grounded conductor with a separately conducted shi...

Page 27: ...d by adjusting the mounting panel Note Always connect shield of cables with a large metal to metal contact surface to shield connection For cable cross sections greater than 25 mm you can use a special mounting plate as shield attachment The following figures show the mounting plate at the drive controller You can mount the mounting plate horizontally or vertically at the drive controller Ap5415f1...

Page 28: ...t Fig 5 19 Design Cross section single wire mm Cross section multi core wire mm Cross section in AWG gauge no 0 14 1 5 0 14 1 5 28 16 Fig 5 20 Connection cross section AP5154F1 FH7 1 2 4 5 E H AC Motor M 3 A1 A2 A3 A B C D X6 holding brake F G 3 6 TM TM BR BR U B 0V B 24VExt 0VExt 24V PTC NTC depends on motor type U HDS 7 XS1 shield for motor cable Fig 5 21 Motor cable holding brake and temperatur...

Page 29: ...ing device When you use an external switching device the control of the holding brake must not be done by the drive controller directly Current consumption of the holding brake is listed in the Project Planning Manual of AC motors The AC motor holding brake is not a dynamic brake It wears down after about 20 000 motor revolutions against the closed brake disc Note To release a holding brake in the...

Page 30: ...t Note For the connection of the drive and control system to the power supply unit it is necessary to distinguish between the arrangement of the units one below the other and one above the other Arranging the units horizontally If the units in the control cabinet are arranged horizontally use the copper strands and PE bridges included in the delivery scope for the power connection of the drive and...

Page 31: ...ndiminished performance requirement If the units in the control cabinet are arranged vertically you need to use twisted single conductors for the power connection of the drive and control systems terminal L L instead of the supplied copper strands The single conductors for the power connection of the drive and control systems may have a maximum length twisted of 1 m Material number of cable 291 26...

Page 32: ... 10 mm2 10 mm2 HVR03 2 W045N 16 mm2 16 mm2 HVE02 2 W018N 10 mm2 10 mm2 10 mm2 HVE03 2 W030N 16 mm2 16 mm2 16 mm2 HVR02 2 W010N 10 mm2 10 mm2 HVE04 2 W075N 50 mm2 25 mm2 35 mm2 6 Flat cable designated INB648 This cable will be necessary if units are not arranged directly next to each other 7 Flat cable designated INB647 This cable will be necessary if units are arranged one below the other or verti...

Page 33: ...dangered 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 signa...

Page 34: ...ard by an undamaged touch guard Keep the cutouts at the touch guard as small as possible Only remove the cutouts if necessary Abb 5 27 Supply unit left and drive controllers with touch guards Sizing of Enclosure and Control Cabinet Control Cabinet with Multiple Line Structure Note Particular attention should be paid to the maximum allowed air intake temperature of components when they are arranged...

Page 35: ...re 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 formed when cooling units are used For this reason please observe the following information Always position cooling units in such a way that condensation water cannot drip on...

Page 36: ...djustment 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 war...

Page 37: ...ontact with 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 have been dimensioned in such a way that after the energy supply was cut off the voltage value falls below 50 V ...

Page 38: ...or 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 disc...

Page 39: ...apacitors discharging 6 1 DC bus voltage 5 8 Dimensions 3 1 Discharging DC bus capacitors 6 1 Documentations Overview 4 1 dripping or sprayed water 5 17 G Ground connections 5 8 Grounded conductor connection 5 8 Grounding brackets 5 8 H Holding brake 5 10 Holding brake control 5 11 I Intermediate circuit motor and power connections 5 8 L Line lengths 5 8 M moisture condensation 5 18 Motor cable 5 ...

Page 40: ...ations 4 1 T Technical data of connector 5 6 5 10 Technical data of connector X5 5 8 Temperature monitor 5 10 Tightening torques X5 5 7 TM TM 5 12 Total connection diagram HDS 5 3 Type codes HDD HDD02 2 W0xx HD32 2 2 Type codes HDS 2 1 Type plates 2 2 X X6 Holding brake motor temperature monitoring 5 10 ...

Page 41: ......

Page 42: ...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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